the haccp food safety employee manual 0471781827

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The HACCP Food Safety Employee Manual Tara Paster John Wiley & Sons, Inc.

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Page 1: The HACCP Food Safety Employee Manual 0471781827

The HACCP FoodSafety Employee

Manual

Tara Paster

John Wiley amp Sons Inc

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File Attachment
C1jpg

The HACCP FoodSafety Employee

Manual

Tara Paster

John Wiley amp Sons Inc

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This book is printed on acid-free paper

Copyright copy 2007 by Tara M Paster All rights reserved

Published by John Wiley amp Sons Inc Hoboken New JerseyPublished simultaneously in Canada

No part of this publication may be reproduced stored in a retrieval system or transmitted inany form or by any means electronic mechanical photocopying recording scanning orotherwise except as permitted under Section 107 or 108 of the 1976 United States Copy-right Act without either the prior written permission of the Publisher or authorizationthrough payment of the appropriate per-copy fee to the Copyright Clearance Center Inc222 Rosewood Drive Danvers MA 01923 (978) 750-8400 fax (978) 750-4470 or on theweb at wwwcopyrightcom Requests to the Publisher for permission should be addressedto the Permissions Department John Wiley amp Sons Inc 111 River Street Hoboken NJ07030 (201) 748-6011 fax (201) 748-6008 e-mail permcoordinatorwileycom

Limits of LiabilityDisclaimer of Warranty While the Publisher and author have used theirbest efforts in preparing this book they make no representations or warranties with re-spect to the accuracy or completeness of the contents of this book and specifically dis-claim any implied warranties of merchantability or fitness for a particular purpose Nowarranty may be created or extended by sales representatives or written sales materialsThe advice and strategies contained herein may not be suitable for your situation Youshould consult with a professional where appropriate Neither the publisher nor authorshall be liable for any loss of profit or any other commercial damages including but notlimited to special incidental consequential or other damages

For general information on our other products and services or for technical supportplease contact our Customer Care Department within the United States at 800-762-2974outside the United States at (317) 572-3993 or fax (317) 572-4002

Wiley also publishes its books in a variety of electronic formats Some content thatappears in print may not be available in electronic books For more information aboutWiley products visit our web site at wwwwileycom

Library of Congress Cataloging-in-Publication Data

Paster Tara 1968-The HACCP food safety employee manual Tara Paster

p cmISBN-13 978-0-471-78182-0 (pbk)ISBN-10 0-471-78182-7 (pbk)1 Food industry and trademdashSafety measures 2 Food handlingmdashHandbooks manu-

als etc 3 Food servicemdashHandbooks manuals etc I Title TX537P29 200666400289mdashdc22

2005035005

Printed in the United States of America

10 9 8 7 6 5 4 3 2 1

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iii

ContentsAcknowledgments 00

Acknowledgments vPreface vii

HACCP STAR POINT 1PREREQUISITE PROGRAMS 1

HACCP Pretest 2Understanding and Using Prerequisite Programs 4Understanding Food Safety Using Standard Operating Procedures 4Star Knowledge SOP Exercise 6Common Foodborne Illnesses 7Major Food Allergens 9Star Knowledge 10International Food Safety Icons 11Food Safety Match Game 12Employee Responsibilities Related to Food Safety 13

Do Not Work If Ill 13

Wash Your Hands 13

No Bare-Hand Contact 14

Do Not Cross-Contaminate 14

Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 16

Temperature Danger Zone (TDZ) 17Be SafemdashMonitor Time and Temperature 17

Cook All Foods Thoroughly 19

Cold Holding 20

Hot Holding 20

Cooling Food 20

Reheating 21

Wash Rinse Sanitize 21

Serving Food and Operating Self-Service Bars 22Serving Food 22

Food Safety for Self-Service Areas 23

Food Safety SOP Star Conclusion 23Are You a Food Safety ldquoSuperstarrdquo 23

HACCP STAR POINT 2FOOD DEFENSE 27

Introduction to Food Defense 28Food Defense 28

Food Safety 28

Food Security 28

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iv Contents

Understanding Food Defense 28Employee Responsibilities in Food Defense 29

Understanding Employee Responsibilities Concerning Food Defense 29

Employee Awareness SOP 29

Customer Awareness SOP 29

Vendor Awareness SOP 30

Facility Awareness SOP 30

Hoaxes 30

Points to Remember 30

Reality Check 31Are You a Food Defense ldquoSuperstarrdquo 31

HACCP STAR POINT 3CREATE A HACCP PLAN 35

HACCP Introduction 36What Is HACCP 36

Why Is HACCP Important 36

The HACCP Philosophy 37Principle 1 Conduct a Hazard Analysis 37

Identify Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 38

Flow of Food 38

Divide Your Menu Items into Categories 41

Principle 2 Determine Critical Control Points 42Critical Control Point Guidelines 42

Food Flow Chart Example 43

HACCP STAR POINT 4WORK THE PLAN 49

Principle 3 Establish Critical Limits 50Star Knowledge Critical Limits Exercise 51Principle 4 Establish Monitoring Procedures 51

How to Monitor 52

Be a Monitoring Star 52

Use Monitoring Forms 52

Star Knowledge Monitoring Exercise 55Principle 5 Identify Corrective Actions 56Star Knowledge Corrective Action Exercise 58

HACCP STAR POINT 5CHECKS AND BALANCES 61

Principle 6 Verify That the System Works 62Principle 7 Record Keeping and Documentation 63HACCP Principles Match Game 67Are You a HACCP ldquoSuperstarrdquo 68

ch00_4597qxd 1222005 345 PM Page iv

Just as you create and execute an effective HACCP Plan with your staff it hastaken the help of a TEAM to complete this Managerrsquos HACCP Training Book Iwould like to recognize the Superstars on my team who helped me to completethis exciting project

Special Acknowledgment to

Carol Gilbert Thank you for being the pioneer and testing this book for the firsttime It is a difficult position to be in to present material to professional hospitalitytrainers that specialize in food safety and HACCP Carol added pizzazz and athorough Powerpoint extravaganza to the Employee HACCP program

Besides the hands-on experience and HACCP expertise you brought to this pro-gram the contributions you made from your perspective as Food Service Directorfor Hempfield School District has really made a difference This gave a differentviewpoint for editing the book to fit the needs of schools throughout the world

Fay Algeo Thank you for your expertise in training communication organizationfeedback and the flow of the book You are very gifted in your ability to make chal-lenging material fun and educational As a Professional Trainer for the hospitalityindustry your field experience with Paster Training Inc came across in the recom-mendations that you made from start to finish All the hours and the tremendousjob you did in our second testing of the book to food handlers made a great im-pact on the entire Employee Manual

Misty Doane Thank you for the time you dedicated to this project Your writingtalent input and editing for this project made a difference in the clarity of the Em-ployee HACCP Manual

Tony Paster Words cannot describe the gratitude I have for my husband during thisHACCP project The technical support you gave me in the creation of forms anddocuments and the marathon of editing adventures we traveled is overwhelming Iappreciate your support dedication and commitment to this HACCP project andme I love you and thank you for everything

ACKNOWLEDGMENTS

v

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vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

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ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 2: The HACCP Food Safety Employee Manual 0471781827

The HACCP FoodSafety Employee

Manual

Tara Paster

John Wiley amp Sons Inc

ch00_4597qxd 1222005 345 PM Page i

This book is printed on acid-free paper

Copyright copy 2007 by Tara M Paster All rights reserved

Published by John Wiley amp Sons Inc Hoboken New JerseyPublished simultaneously in Canada

No part of this publication may be reproduced stored in a retrieval system or transmitted inany form or by any means electronic mechanical photocopying recording scanning orotherwise except as permitted under Section 107 or 108 of the 1976 United States Copy-right Act without either the prior written permission of the Publisher or authorizationthrough payment of the appropriate per-copy fee to the Copyright Clearance Center Inc222 Rosewood Drive Danvers MA 01923 (978) 750-8400 fax (978) 750-4470 or on theweb at wwwcopyrightcom Requests to the Publisher for permission should be addressedto the Permissions Department John Wiley amp Sons Inc 111 River Street Hoboken NJ07030 (201) 748-6011 fax (201) 748-6008 e-mail permcoordinatorwileycom

Limits of LiabilityDisclaimer of Warranty While the Publisher and author have used theirbest efforts in preparing this book they make no representations or warranties with re-spect to the accuracy or completeness of the contents of this book and specifically dis-claim any implied warranties of merchantability or fitness for a particular purpose Nowarranty may be created or extended by sales representatives or written sales materialsThe advice and strategies contained herein may not be suitable for your situation Youshould consult with a professional where appropriate Neither the publisher nor authorshall be liable for any loss of profit or any other commercial damages including but notlimited to special incidental consequential or other damages

For general information on our other products and services or for technical supportplease contact our Customer Care Department within the United States at 800-762-2974outside the United States at (317) 572-3993 or fax (317) 572-4002

Wiley also publishes its books in a variety of electronic formats Some content thatappears in print may not be available in electronic books For more information aboutWiley products visit our web site at wwwwileycom

Library of Congress Cataloging-in-Publication Data

Paster Tara 1968-The HACCP food safety employee manual Tara Paster

p cmISBN-13 978-0-471-78182-0 (pbk)ISBN-10 0-471-78182-7 (pbk)1 Food industry and trademdashSafety measures 2 Food handlingmdashHandbooks manu-

als etc 3 Food servicemdashHandbooks manuals etc I Title TX537P29 200666400289mdashdc22

2005035005

Printed in the United States of America

10 9 8 7 6 5 4 3 2 1

ch00_4597qxd 121405 1023 AM Page ii

iii

ContentsAcknowledgments 00

Acknowledgments vPreface vii

HACCP STAR POINT 1PREREQUISITE PROGRAMS 1

HACCP Pretest 2Understanding and Using Prerequisite Programs 4Understanding Food Safety Using Standard Operating Procedures 4Star Knowledge SOP Exercise 6Common Foodborne Illnesses 7Major Food Allergens 9Star Knowledge 10International Food Safety Icons 11Food Safety Match Game 12Employee Responsibilities Related to Food Safety 13

Do Not Work If Ill 13

Wash Your Hands 13

No Bare-Hand Contact 14

Do Not Cross-Contaminate 14

Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 16

Temperature Danger Zone (TDZ) 17Be SafemdashMonitor Time and Temperature 17

Cook All Foods Thoroughly 19

Cold Holding 20

Hot Holding 20

Cooling Food 20

Reheating 21

Wash Rinse Sanitize 21

Serving Food and Operating Self-Service Bars 22Serving Food 22

Food Safety for Self-Service Areas 23

Food Safety SOP Star Conclusion 23Are You a Food Safety ldquoSuperstarrdquo 23

HACCP STAR POINT 2FOOD DEFENSE 27

Introduction to Food Defense 28Food Defense 28

Food Safety 28

Food Security 28

ch00_4597qxd 1222005 345 PM Page iii

iv Contents

Understanding Food Defense 28Employee Responsibilities in Food Defense 29

Understanding Employee Responsibilities Concerning Food Defense 29

Employee Awareness SOP 29

Customer Awareness SOP 29

Vendor Awareness SOP 30

Facility Awareness SOP 30

Hoaxes 30

Points to Remember 30

Reality Check 31Are You a Food Defense ldquoSuperstarrdquo 31

HACCP STAR POINT 3CREATE A HACCP PLAN 35

HACCP Introduction 36What Is HACCP 36

Why Is HACCP Important 36

The HACCP Philosophy 37Principle 1 Conduct a Hazard Analysis 37

Identify Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 38

Flow of Food 38

Divide Your Menu Items into Categories 41

Principle 2 Determine Critical Control Points 42Critical Control Point Guidelines 42

Food Flow Chart Example 43

HACCP STAR POINT 4WORK THE PLAN 49

Principle 3 Establish Critical Limits 50Star Knowledge Critical Limits Exercise 51Principle 4 Establish Monitoring Procedures 51

How to Monitor 52

Be a Monitoring Star 52

Use Monitoring Forms 52

Star Knowledge Monitoring Exercise 55Principle 5 Identify Corrective Actions 56Star Knowledge Corrective Action Exercise 58

HACCP STAR POINT 5CHECKS AND BALANCES 61

Principle 6 Verify That the System Works 62Principle 7 Record Keeping and Documentation 63HACCP Principles Match Game 67Are You a HACCP ldquoSuperstarrdquo 68

ch00_4597qxd 1222005 345 PM Page iv

Just as you create and execute an effective HACCP Plan with your staff it hastaken the help of a TEAM to complete this Managerrsquos HACCP Training Book Iwould like to recognize the Superstars on my team who helped me to completethis exciting project

Special Acknowledgment to

Carol Gilbert Thank you for being the pioneer and testing this book for the firsttime It is a difficult position to be in to present material to professional hospitalitytrainers that specialize in food safety and HACCP Carol added pizzazz and athorough Powerpoint extravaganza to the Employee HACCP program

Besides the hands-on experience and HACCP expertise you brought to this pro-gram the contributions you made from your perspective as Food Service Directorfor Hempfield School District has really made a difference This gave a differentviewpoint for editing the book to fit the needs of schools throughout the world

Fay Algeo Thank you for your expertise in training communication organizationfeedback and the flow of the book You are very gifted in your ability to make chal-lenging material fun and educational As a Professional Trainer for the hospitalityindustry your field experience with Paster Training Inc came across in the recom-mendations that you made from start to finish All the hours and the tremendousjob you did in our second testing of the book to food handlers made a great im-pact on the entire Employee Manual

Misty Doane Thank you for the time you dedicated to this project Your writingtalent input and editing for this project made a difference in the clarity of the Em-ployee HACCP Manual

Tony Paster Words cannot describe the gratitude I have for my husband during thisHACCP project The technical support you gave me in the creation of forms anddocuments and the marathon of editing adventures we traveled is overwhelming Iappreciate your support dedication and commitment to this HACCP project andme I love you and thank you for everything

ACKNOWLEDGMENTS

v

ch00_4597qxd 1222005 345 PM Page v

vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 3: The HACCP Food Safety Employee Manual 0471781827

This book is printed on acid-free paper

Copyright copy 2007 by Tara M Paster All rights reserved

Published by John Wiley amp Sons Inc Hoboken New JerseyPublished simultaneously in Canada

No part of this publication may be reproduced stored in a retrieval system or transmitted inany form or by any means electronic mechanical photocopying recording scanning orotherwise except as permitted under Section 107 or 108 of the 1976 United States Copy-right Act without either the prior written permission of the Publisher or authorizationthrough payment of the appropriate per-copy fee to the Copyright Clearance Center Inc222 Rosewood Drive Danvers MA 01923 (978) 750-8400 fax (978) 750-4470 or on theweb at wwwcopyrightcom Requests to the Publisher for permission should be addressedto the Permissions Department John Wiley amp Sons Inc 111 River Street Hoboken NJ07030 (201) 748-6011 fax (201) 748-6008 e-mail permcoordinatorwileycom

Limits of LiabilityDisclaimer of Warranty While the Publisher and author have used theirbest efforts in preparing this book they make no representations or warranties with re-spect to the accuracy or completeness of the contents of this book and specifically dis-claim any implied warranties of merchantability or fitness for a particular purpose Nowarranty may be created or extended by sales representatives or written sales materialsThe advice and strategies contained herein may not be suitable for your situation Youshould consult with a professional where appropriate Neither the publisher nor authorshall be liable for any loss of profit or any other commercial damages including but notlimited to special incidental consequential or other damages

For general information on our other products and services or for technical supportplease contact our Customer Care Department within the United States at 800-762-2974outside the United States at (317) 572-3993 or fax (317) 572-4002

Wiley also publishes its books in a variety of electronic formats Some content thatappears in print may not be available in electronic books For more information aboutWiley products visit our web site at wwwwileycom

Library of Congress Cataloging-in-Publication Data

Paster Tara 1968-The HACCP food safety employee manual Tara Paster

p cmISBN-13 978-0-471-78182-0 (pbk)ISBN-10 0-471-78182-7 (pbk)1 Food industry and trademdashSafety measures 2 Food handlingmdashHandbooks manu-

als etc 3 Food servicemdashHandbooks manuals etc I Title TX537P29 200666400289mdashdc22

2005035005

Printed in the United States of America

10 9 8 7 6 5 4 3 2 1

ch00_4597qxd 121405 1023 AM Page ii

iii

ContentsAcknowledgments 00

Acknowledgments vPreface vii

HACCP STAR POINT 1PREREQUISITE PROGRAMS 1

HACCP Pretest 2Understanding and Using Prerequisite Programs 4Understanding Food Safety Using Standard Operating Procedures 4Star Knowledge SOP Exercise 6Common Foodborne Illnesses 7Major Food Allergens 9Star Knowledge 10International Food Safety Icons 11Food Safety Match Game 12Employee Responsibilities Related to Food Safety 13

Do Not Work If Ill 13

Wash Your Hands 13

No Bare-Hand Contact 14

Do Not Cross-Contaminate 14

Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 16

Temperature Danger Zone (TDZ) 17Be SafemdashMonitor Time and Temperature 17

Cook All Foods Thoroughly 19

Cold Holding 20

Hot Holding 20

Cooling Food 20

Reheating 21

Wash Rinse Sanitize 21

Serving Food and Operating Self-Service Bars 22Serving Food 22

Food Safety for Self-Service Areas 23

Food Safety SOP Star Conclusion 23Are You a Food Safety ldquoSuperstarrdquo 23

HACCP STAR POINT 2FOOD DEFENSE 27

Introduction to Food Defense 28Food Defense 28

Food Safety 28

Food Security 28

ch00_4597qxd 1222005 345 PM Page iii

iv Contents

Understanding Food Defense 28Employee Responsibilities in Food Defense 29

Understanding Employee Responsibilities Concerning Food Defense 29

Employee Awareness SOP 29

Customer Awareness SOP 29

Vendor Awareness SOP 30

Facility Awareness SOP 30

Hoaxes 30

Points to Remember 30

Reality Check 31Are You a Food Defense ldquoSuperstarrdquo 31

HACCP STAR POINT 3CREATE A HACCP PLAN 35

HACCP Introduction 36What Is HACCP 36

Why Is HACCP Important 36

The HACCP Philosophy 37Principle 1 Conduct a Hazard Analysis 37

Identify Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 38

Flow of Food 38

Divide Your Menu Items into Categories 41

Principle 2 Determine Critical Control Points 42Critical Control Point Guidelines 42

Food Flow Chart Example 43

HACCP STAR POINT 4WORK THE PLAN 49

Principle 3 Establish Critical Limits 50Star Knowledge Critical Limits Exercise 51Principle 4 Establish Monitoring Procedures 51

How to Monitor 52

Be a Monitoring Star 52

Use Monitoring Forms 52

Star Knowledge Monitoring Exercise 55Principle 5 Identify Corrective Actions 56Star Knowledge Corrective Action Exercise 58

HACCP STAR POINT 5CHECKS AND BALANCES 61

Principle 6 Verify That the System Works 62Principle 7 Record Keeping and Documentation 63HACCP Principles Match Game 67Are You a HACCP ldquoSuperstarrdquo 68

ch00_4597qxd 1222005 345 PM Page iv

Just as you create and execute an effective HACCP Plan with your staff it hastaken the help of a TEAM to complete this Managerrsquos HACCP Training Book Iwould like to recognize the Superstars on my team who helped me to completethis exciting project

Special Acknowledgment to

Carol Gilbert Thank you for being the pioneer and testing this book for the firsttime It is a difficult position to be in to present material to professional hospitalitytrainers that specialize in food safety and HACCP Carol added pizzazz and athorough Powerpoint extravaganza to the Employee HACCP program

Besides the hands-on experience and HACCP expertise you brought to this pro-gram the contributions you made from your perspective as Food Service Directorfor Hempfield School District has really made a difference This gave a differentviewpoint for editing the book to fit the needs of schools throughout the world

Fay Algeo Thank you for your expertise in training communication organizationfeedback and the flow of the book You are very gifted in your ability to make chal-lenging material fun and educational As a Professional Trainer for the hospitalityindustry your field experience with Paster Training Inc came across in the recom-mendations that you made from start to finish All the hours and the tremendousjob you did in our second testing of the book to food handlers made a great im-pact on the entire Employee Manual

Misty Doane Thank you for the time you dedicated to this project Your writingtalent input and editing for this project made a difference in the clarity of the Em-ployee HACCP Manual

Tony Paster Words cannot describe the gratitude I have for my husband during thisHACCP project The technical support you gave me in the creation of forms anddocuments and the marathon of editing adventures we traveled is overwhelming Iappreciate your support dedication and commitment to this HACCP project andme I love you and thank you for everything

ACKNOWLEDGMENTS

v

ch00_4597qxd 1222005 345 PM Page v

vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 4: The HACCP Food Safety Employee Manual 0471781827

iii

ContentsAcknowledgments 00

Acknowledgments vPreface vii

HACCP STAR POINT 1PREREQUISITE PROGRAMS 1

HACCP Pretest 2Understanding and Using Prerequisite Programs 4Understanding Food Safety Using Standard Operating Procedures 4Star Knowledge SOP Exercise 6Common Foodborne Illnesses 7Major Food Allergens 9Star Knowledge 10International Food Safety Icons 11Food Safety Match Game 12Employee Responsibilities Related to Food Safety 13

Do Not Work If Ill 13

Wash Your Hands 13

No Bare-Hand Contact 14

Do Not Cross-Contaminate 14

Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 16

Temperature Danger Zone (TDZ) 17Be SafemdashMonitor Time and Temperature 17

Cook All Foods Thoroughly 19

Cold Holding 20

Hot Holding 20

Cooling Food 20

Reheating 21

Wash Rinse Sanitize 21

Serving Food and Operating Self-Service Bars 22Serving Food 22

Food Safety for Self-Service Areas 23

Food Safety SOP Star Conclusion 23Are You a Food Safety ldquoSuperstarrdquo 23

HACCP STAR POINT 2FOOD DEFENSE 27

Introduction to Food Defense 28Food Defense 28

Food Safety 28

Food Security 28

ch00_4597qxd 1222005 345 PM Page iii

iv Contents

Understanding Food Defense 28Employee Responsibilities in Food Defense 29

Understanding Employee Responsibilities Concerning Food Defense 29

Employee Awareness SOP 29

Customer Awareness SOP 29

Vendor Awareness SOP 30

Facility Awareness SOP 30

Hoaxes 30

Points to Remember 30

Reality Check 31Are You a Food Defense ldquoSuperstarrdquo 31

HACCP STAR POINT 3CREATE A HACCP PLAN 35

HACCP Introduction 36What Is HACCP 36

Why Is HACCP Important 36

The HACCP Philosophy 37Principle 1 Conduct a Hazard Analysis 37

Identify Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 38

Flow of Food 38

Divide Your Menu Items into Categories 41

Principle 2 Determine Critical Control Points 42Critical Control Point Guidelines 42

Food Flow Chart Example 43

HACCP STAR POINT 4WORK THE PLAN 49

Principle 3 Establish Critical Limits 50Star Knowledge Critical Limits Exercise 51Principle 4 Establish Monitoring Procedures 51

How to Monitor 52

Be a Monitoring Star 52

Use Monitoring Forms 52

Star Knowledge Monitoring Exercise 55Principle 5 Identify Corrective Actions 56Star Knowledge Corrective Action Exercise 58

HACCP STAR POINT 5CHECKS AND BALANCES 61

Principle 6 Verify That the System Works 62Principle 7 Record Keeping and Documentation 63HACCP Principles Match Game 67Are You a HACCP ldquoSuperstarrdquo 68

ch00_4597qxd 1222005 345 PM Page iv

Just as you create and execute an effective HACCP Plan with your staff it hastaken the help of a TEAM to complete this Managerrsquos HACCP Training Book Iwould like to recognize the Superstars on my team who helped me to completethis exciting project

Special Acknowledgment to

Carol Gilbert Thank you for being the pioneer and testing this book for the firsttime It is a difficult position to be in to present material to professional hospitalitytrainers that specialize in food safety and HACCP Carol added pizzazz and athorough Powerpoint extravaganza to the Employee HACCP program

Besides the hands-on experience and HACCP expertise you brought to this pro-gram the contributions you made from your perspective as Food Service Directorfor Hempfield School District has really made a difference This gave a differentviewpoint for editing the book to fit the needs of schools throughout the world

Fay Algeo Thank you for your expertise in training communication organizationfeedback and the flow of the book You are very gifted in your ability to make chal-lenging material fun and educational As a Professional Trainer for the hospitalityindustry your field experience with Paster Training Inc came across in the recom-mendations that you made from start to finish All the hours and the tremendousjob you did in our second testing of the book to food handlers made a great im-pact on the entire Employee Manual

Misty Doane Thank you for the time you dedicated to this project Your writingtalent input and editing for this project made a difference in the clarity of the Em-ployee HACCP Manual

Tony Paster Words cannot describe the gratitude I have for my husband during thisHACCP project The technical support you gave me in the creation of forms anddocuments and the marathon of editing adventures we traveled is overwhelming Iappreciate your support dedication and commitment to this HACCP project andme I love you and thank you for everything

ACKNOWLEDGMENTS

v

ch00_4597qxd 1222005 345 PM Page v

vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 5: The HACCP Food Safety Employee Manual 0471781827

iv Contents

Understanding Food Defense 28Employee Responsibilities in Food Defense 29

Understanding Employee Responsibilities Concerning Food Defense 29

Employee Awareness SOP 29

Customer Awareness SOP 29

Vendor Awareness SOP 30

Facility Awareness SOP 30

Hoaxes 30

Points to Remember 30

Reality Check 31Are You a Food Defense ldquoSuperstarrdquo 31

HACCP STAR POINT 3CREATE A HACCP PLAN 35

HACCP Introduction 36What Is HACCP 36

Why Is HACCP Important 36

The HACCP Philosophy 37Principle 1 Conduct a Hazard Analysis 37

Identify Potentially Hazardous FoodmdashTimeTemperature Control for Safety of Food (PHFTCS) 38

Flow of Food 38

Divide Your Menu Items into Categories 41

Principle 2 Determine Critical Control Points 42Critical Control Point Guidelines 42

Food Flow Chart Example 43

HACCP STAR POINT 4WORK THE PLAN 49

Principle 3 Establish Critical Limits 50Star Knowledge Critical Limits Exercise 51Principle 4 Establish Monitoring Procedures 51

How to Monitor 52

Be a Monitoring Star 52

Use Monitoring Forms 52

Star Knowledge Monitoring Exercise 55Principle 5 Identify Corrective Actions 56Star Knowledge Corrective Action Exercise 58

HACCP STAR POINT 5CHECKS AND BALANCES 61

Principle 6 Verify That the System Works 62Principle 7 Record Keeping and Documentation 63HACCP Principles Match Game 67Are You a HACCP ldquoSuperstarrdquo 68

ch00_4597qxd 1222005 345 PM Page iv

Just as you create and execute an effective HACCP Plan with your staff it hastaken the help of a TEAM to complete this Managerrsquos HACCP Training Book Iwould like to recognize the Superstars on my team who helped me to completethis exciting project

Special Acknowledgment to

Carol Gilbert Thank you for being the pioneer and testing this book for the firsttime It is a difficult position to be in to present material to professional hospitalitytrainers that specialize in food safety and HACCP Carol added pizzazz and athorough Powerpoint extravaganza to the Employee HACCP program

Besides the hands-on experience and HACCP expertise you brought to this pro-gram the contributions you made from your perspective as Food Service Directorfor Hempfield School District has really made a difference This gave a differentviewpoint for editing the book to fit the needs of schools throughout the world

Fay Algeo Thank you for your expertise in training communication organizationfeedback and the flow of the book You are very gifted in your ability to make chal-lenging material fun and educational As a Professional Trainer for the hospitalityindustry your field experience with Paster Training Inc came across in the recom-mendations that you made from start to finish All the hours and the tremendousjob you did in our second testing of the book to food handlers made a great im-pact on the entire Employee Manual

Misty Doane Thank you for the time you dedicated to this project Your writingtalent input and editing for this project made a difference in the clarity of the Em-ployee HACCP Manual

Tony Paster Words cannot describe the gratitude I have for my husband during thisHACCP project The technical support you gave me in the creation of forms anddocuments and the marathon of editing adventures we traveled is overwhelming Iappreciate your support dedication and commitment to this HACCP project andme I love you and thank you for everything

ACKNOWLEDGMENTS

v

ch00_4597qxd 1222005 345 PM Page v

vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 6: The HACCP Food Safety Employee Manual 0471781827

Just as you create and execute an effective HACCP Plan with your staff it hastaken the help of a TEAM to complete this Managerrsquos HACCP Training Book Iwould like to recognize the Superstars on my team who helped me to completethis exciting project

Special Acknowledgment to

Carol Gilbert Thank you for being the pioneer and testing this book for the firsttime It is a difficult position to be in to present material to professional hospitalitytrainers that specialize in food safety and HACCP Carol added pizzazz and athorough Powerpoint extravaganza to the Employee HACCP program

Besides the hands-on experience and HACCP expertise you brought to this pro-gram the contributions you made from your perspective as Food Service Directorfor Hempfield School District has really made a difference This gave a differentviewpoint for editing the book to fit the needs of schools throughout the world

Fay Algeo Thank you for your expertise in training communication organizationfeedback and the flow of the book You are very gifted in your ability to make chal-lenging material fun and educational As a Professional Trainer for the hospitalityindustry your field experience with Paster Training Inc came across in the recom-mendations that you made from start to finish All the hours and the tremendousjob you did in our second testing of the book to food handlers made a great im-pact on the entire Employee Manual

Misty Doane Thank you for the time you dedicated to this project Your writingtalent input and editing for this project made a difference in the clarity of the Em-ployee HACCP Manual

Tony Paster Words cannot describe the gratitude I have for my husband during thisHACCP project The technical support you gave me in the creation of forms anddocuments and the marathon of editing adventures we traveled is overwhelming Iappreciate your support dedication and commitment to this HACCP project andme I love you and thank you for everything

ACKNOWLEDGMENTS

v

ch00_4597qxd 1222005 345 PM Page v

vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

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ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

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ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 7: The HACCP Food Safety Employee Manual 0471781827

vi Acknowledgments

Extra Special Thanks goes to

JoAnna Turtletaub Thank you for giving me this opportunity to impact the schoolfoodservice and the hospitality industry with HACCP for employees managersand instructors throughout the world

Nigar Hale Julie Kerr and Cindy Rhoads This is the dynamic trio at Wiley thatlead me through this electrifying process I have a huge appreciation for their com-mitment and genuine interest in this project I was very impressed when the ladiesparticipated in our Derry Township School District Employee HACCP training testto help in consulting and monitoring the food handlersrsquo feedback of this new andstimulating resource

The Wiley Production Team WOW For the Wiley Production Team including allthe editors the designer compositor and artists thank you for your patience andunderstanding especially after each field test that generated rewrites and morerewrites and even more rewrites

This entire HACCP Writing Team (Carol Fay Misty Tony JoAnna Nigar Julie Cindyand the Wiley Production Team) is an incredible group of professionals who de-serve special acknowledgment and recognition for outstanding efforts

OUR MISSIONTo minimize consumer risk of acquiring a foodborne illness to prevent having

an allergic reaction to food and to avoid suffering an injury from foods consumedin any foodservice operation around the world

ch00_4597qxd 1222005 345 PM Page vi

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 8: The HACCP Food Safety Employee Manual 0471781827

vii

HACCP Star Points to Food Safety

No matter where you are in the world on a clear night you can look up in the skyand see the millions of sparkling stars in our solar system These millions ofsparkling stars are all unique and different just like the millions of foodservice op-erations of the world That is why every operation serving or selling food needs tohave a food safety system in place that is designed specifically to guarantee thefood being served is safe to eat This specific food safety system is called HACCP(pronounced ldquohas-siprdquo) for Hazard Analysis and Critical Control Point HACCP isa system comprised of 7 principles that are to be applied to a written food safetyprogram focusing on the food in your operation HACCP proves that what you door donrsquot do makes a big difference in serving safe food The goal of HACCP is tostop control and prevent food safety problems Our goal for you in this sessionis for you to be a HACCP Superstar

This HACCP system is very important because it saves lives The CDC (Centersfor Disease Control and Prevention) estimates that every year 76 million peopleget sick and 5000 people die from eating unsafe food The HACCP program re-quires every team member in the foodservice industry to be responsible and toensure that the food he or she prepares and serves to customers is not hazardousto their health

Prerequisite programs such as food safety and food defense standards of opera-tion are the building blocks for creating an effective HACCP planmdashif any membersof the foodservice operation do not follow these standard operating procedures(SOPs) even the most well thought out HACCP plan will fail To ensure the de-velopment of an effective HACCP plan for your establishment the basics of foodsafety and food defense standard operating procedures must be reviewed This iswhat will be covered in the first two chapters of this book Once the basics of foodsafety and food defense standard operating procedures are reviewed the bookwill then cover how a HACCP plan is created and how to use an effectiveHACCP plan for your foodservice establishment

Preface

ch00_4597qxd 1222005 345 PM Page vii

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 9: The HACCP Food Safety Employee Manual 0471781827

viii Preface

THE HACCP STARThe goal of this HACCP training program is to make you a HACCP Superstar

To be a HACCP Superstar you must shine on all five points of the HACCP Star Hereis the HACCP Star and the five major points that define a successful HACCPsystem

Master Prerequisite Programs

Apply Food Defense

Evaluate Hazards and Critical Control Points

Manage Critical Limits Monitoring and Corrective Actions

Confirm by Record Keeping Documentation

Your Employee HACCP Certificate expires in four years so it is critical to keep yourcertification current Always reach for the stars Once you read through this entiremanual you will be able to

Identify the causes of foodborne illnesses

Identify the key points of HACCP

Explain the 7 HACCP principles

Follow prerequisite programs for food safety

Apply standard operating procedures for food safety and food de-fense in your operation

Identify the three classifications of recipes

Determine critical control points

Apply correct critical limits

Complete monitoring forms

Determine effective corrective actions

ch00_4597qxd 1222005 345 PM Page viii

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 10: The HACCP Food Safety Employee Manual 0471781827

Preface ix

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

HACCP

Point 2 Food Defense bull Apply

ch00_4597qxd 1222005 345 PM Page ix

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 11: The HACCP Food Safety Employee Manual 0471781827

ch00_4597qxd 1222005 345 PM Page x

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 12: The HACCP Food Safety Employee Manual 0471781827

In Star Point 1 we will discuss the basics of prerequisite programs and food safetystandard operating procedures We must be aware of how food can become unsafeWe must also have rules and procedures in place to prevent the food from becom-ing unsafe The established prerequisite programs and standard operating proce-dures can then be incorporated into a HACCP plan

1

Prerequisite Programs

Point 1 Prerequisite Programs bull Master

HACCP

HACCP STAR POINT 1

Star Point Actions You will learn to

Define HACCP and its goals

Identify the causes for foodborne illness

Understand how HACCP controls foodborne illness outbreaks

Assist customers who have food allergies

Recognize and understand the importance of Standard Operating Procedures

Identify the International Food Safety Icons

ch01_4597qxd 1262005 124 PM Page 1

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

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ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 13: The HACCP Food Safety Employee Manual 0471781827

Initially you will need to take a HACCP Pretest to measure your current foodsafety food defense and HACCP knowledge It is important to do this pretest be-cause this allows your trainer to measure your success as you work toward yourHACCP Superstar Certificate Letrsquos get started

2 HACCP Star Point 1

Apply time and temperatures controls to ensure food safety

Prevent contamination of food

Explain employee personal responsibilities for food safety

Explain the difference between cleaning and sanitizing

HACCP PRETEST

1 What Is HACCP

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

2 Conducting a hazard analysis means

a ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat are the standard operating proceduresrdquob ldquoWhat is the likelihood of a hazard to occurrdquo and ldquoWhat is the risk if the hazard does occurrdquoc You are watching coworkers as they prepare food to make sure they are following the proper procedures

and avoiding hazardous chemicals

3 A critical control point (CCP) is

a An essential step in the product-handling process where controls can be applied and a food safety haz-ard can be prevented eliminated or reduced to acceptable levels

b One of the last chances you have to be sure the food will be safe when you serve itc Both a and b

4 Record keeping includes

a Checklistsb Records of employee trainingc Both a and b

5 What is an SOP

a Single Opportunity Planb Special Operating Proceduresc Standard Operating Procedures

6 Critical limits can be

a Cleaning food-contact surfacesb Cooking foods to a specific temperature for a specific amount of timec Measuring the limits of how long you can cook food before it burns

7 Foods need to be cooked to a specific temperature because

a Most people like food well-doneb The right time and temperature is the only way to make sure itrsquos safe to eatc You donrsquot want to ldquoovercookrdquo the food if you have to warm it up later

ch01_4597qxd 1262005 124 PM Page 2

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 14: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 3

8 What is RTE

a Ready to Eatb Right through Eatingc Ready to Execute

9 Monitoring procedures

a Ensure that we are correctly meeting critical limits for the CCPsb Are what employees do to make sure customers are buying the food at the food barc How disposed food affects the profitloss statement

10 What is food defense

a Preventing the deliberate contamination of foodb Blocking customers from the kitchenc A new national government office that reports to the Department of Homeland Security

11 An example of a corrective action is

a Receiving a written warningb Showing a coworker how to take shortcuts while preparing foodc Rejecting a product that does not meet purchasing or receiving specifications

12 Which is not a form of verification for a HACCP plan

a Checking equipment temperaturesb Checking critical control point recordsc Making sure you are wearing a clean uniform

13 What is the temperature danger zone

a 45ordmFndash140ordmF (72ordmCndash60ordmC)b 35ordmFndash140ordmF (17ordmCndash60ordmC)c 41ordmFndash135ordmF (5ordmCndash572ordmC)

14 What are the characteristics of potentially hazardous foods timetemperature control for safety of food(PHFTCS)

a Dry low acidity vegetable basedb Moist neutral acidity proteinc Moist sugary low fat

15 What is food security

a A two-year supply of food for a countryb Designating an employee to watch the buffetc A newly appointed government office

How many points did you earn _____

If you scored 14ndash15 pointsmdashCongratulations You are very knowledgeable already about HACCP

If you scored 9ndash13 pointsmdashGood job You have a basic understanding of HACCP and all of itscomponents

If you scored 5ndash8 pointsmdashThere is no time like the present to learn about HACCP This book willgive you a great opportunity to fine-tune your HACCP skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

It is important to track your progress as you complete each point of the star to earn your HACCPSuperstar Certificate

ch01_4597qxd 1262005 124 PM Page 3

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 15: The HACCP Food Safety Employee Manual 0471781827

4 HACCP Star Point 1

UNDERSTANDING AND USINGPREREQUISITE PROGRAMSPrerequisite programs are basic operational and foundational requirements

needs for an effective HACCP plan Prerequisite programs used in mostfoodservice operations include

Training

Food safety

Sanitation

Standard operating procedures

Personal hygiene

Employee health

Product instructions (recipe and process)

Equipment

Facility design

Supplier selection and control

Product specifications

Major food allergen management

Chemical and pest control

Food defense

Food recall procedures

Crisis management

Prerequisite programs must be in place before any food should enter a foodestablishment Once these programs are in place and shown to all employeesfollowing and mastering the directives in the standard operating procedures canensure the safe flow of food through your establishment

UNDERSTANDING FOOD SAFETY USINGSTANDARD OPERATING PROCEDURESStandard Operating Procedures (SOPs) are required for all HACCP plans

They provide the acceptable practices and procedures that your foodserviceorganization requires you to follow SOPs are only effective if they are followed Wewill now define standard operating procedures in detail and provide an example ofone It is important for you to understand that SOPs play a large part in yourHACCP plan and the safety of your facility and the food served

Approved HACCP plans require that each employee follow SOPs at each step inthe flow of food These are standards you must know and practice when purchas-ing receiving storing preparing cooking holding cooling reheating and servingfood Job descriptions should make it clear that all employees are expected to fol-low standard operating procedures

What you do or donrsquot do as an employee in the foodservice industry is importantto public health Your training in food safety could actually save lives and help raisethe quality of food served at your establishment Most importantly you can makea difference by following standard operating procedures and by making sounddecisions that will help keep your customers safe Here is an example of a Receiv-ing SOP

ch01_4597qxd 1262005 124 PM Page 4

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 16: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 5

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who receive handle prepare or servefood

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before receivingdeliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitor See Star Point 4HACCP Principle 4

Corrective Action See Star Point 4HACCP Principle 5

Verification See Star Point 5HACCP Principle 6

Record KeepingDocumentation See Star Point 5HACCP Principle 7

ch01_4597qxd 1262005 124 PM Page 5

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

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ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 17: The HACCP Food Safety Employee Manual 0471781827

If SOPs arenrsquot followed you and your customers may contract a foodborne illnessIllnesses that travel to you through food are called foodborne illnesses A food-borne illness is caused by eating food that has dangerous germs called pathogenswhich grow in your body and then make you sick Everyday we eat pathogens butmost people have enough antibodies to fight off pathogens that are ingested How-

6 HACCP Star Point 1

Storage SOP

Purpose To ensure that food is stored safely and put away as quickly as possible after it entersthe foodservice operation

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures storing dry storage refrigeration freezer

Instructions

1

2

3

4

5

6

7

8

9

10

STAR KNOWLEDGE SOP EXERCISE

In the space provided below list the procedures needed for a Storage SOP

ch01_4597qxd 1262005 124 PM Page 6

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 18: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 7

bull Do you serve any of thesepeople in your home

bull Do you serve any of thesepeople at work

ever if there are more pathogens in a body than antibodies then the germs win andwe get sick An outbreak occurs when two or more people eat the same food andget the same illness Following a HACCP program helps prevent foodborne illnessoutbreaks because HACCP is a pro-active approach to control every step in the flowof food

Have you ever eaten food that made you sick

Did you vomit

Did you have stomach cramps

Did you have diarrhea

Did you cough up worms

Experiencing vomiting diarrhea stomach cramps and flu-like symptoms are themost common symptoms associated with foodborne illnesses These symptomscould be a result of not following prerequisite programs and standard operatingprocedures This chapter should help you to understand food safety so that youcan protect yourself your family your friends your neighbors your fellow employ-ees and most of all your customers

The people at the most risk for Foodborne Illness are

Children

People already sick

People taking medication

Pregnant women

Elderly people

COMMON FOODBORNE ILLNESSESThese illnesses are the most alarming because they are highly contagious

and very serious As soon as you find out you have contracted or have beenexposed to any of these illnesses notify your manager immediately

The five highly contagious foodborne illnesses (known as the ldquoBIG 5rdquo) you needto know

Salmonellosis

Shigellosis

Hemorrhagic colitis (better known as E coli)

Hepatitis A

Norovirus

Letrsquos review these foodborne illnesses and their most common causes in greaterdetail

Disease Typically a result of

Salmonellosis Improper handling and cooking ofeggs poultry and meat contami-nated raw fruits and vegetables

ch01_4597qxd 1262005 124 PM Page 7

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 19: The HACCP Food Safety Employee Manual 0471781827

8 HACCP Star Point 1

Bacteria Virus Parasite

Clostridium Perfingens Norovirus Trichinosis

Staphylococcal Gastroenteritis Rotavirus Gastroenteritis Anisakiasis

Campylobacter Hepatitis A Giardiasis

Bacillus Cereus Toxoplasmosis

Botulism Cyclosporiasis

Listeriosis Cryptosporidiosis

Yersiniosis

Vibrio

Salmonellosis(Salmonella)

Shigellosis(Bacillary Dysentery)

Hemorrhagic colitis(E coli)

Disease Typically a result of

Shigellosis (Bacillary Dysentery) Flies water and foods contaminatedwith fecal matter

Hemorrhagic colitis (E coli) Undercooked ground beef unpas-teurized juicecider and dairy prod-ucts and contact with infectedanimals

Hepatitis A Not washing hands properly infectedemployee receiving shellfish fromunapproved sources handling RTEfoods water and ice with contami-nated hands

Norovirus Poor personal hygiene receivingshellfish from unapproved sourcesand using unsanitarynonchlorinatedwater Easily passed among peoplein close quarters for long periods oftime (dormitories offices and cruiseships) Highly contagiousmdashmustreport to person-in-charge

These illnesses are especially crucial to know because they are highly conta-gious and very serious sometimes fatal Again as soon as you find out you havebeen exposed to or have contracted any of these illnesses notify your managerimmediately

ch01_4597qxd 1262005 124 PM Page 8

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 20: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 9

Following prerequisite programs and food safety standard operating procedureswill help to prevent diseases like these from occurring or spreading If you preventa foodborne illness from occurring then you prevent an outbreak If you preventan outbreak you save lives If you save lives you can feel good about what youdo for a living and ultimately protect othersmdashand yourself

MAJOR FOOD ALLERGENSSome of the symptoms associated with a foodborne illness are the same

symptoms associated with an allergic reaction When it comes to food safetyallergies are just as dangerous as foodborne illnesses

Is your customer having an allergic reaction to food Letrsquos find out

Is your customerrsquos throat getting tight

Does your customer have shortness of breath

Does your customer have itching around the mouth

Does your customer have hives

Anyone can be allergic to anything Sometimes people donrsquot know they have afood allergy until they have a reaction to a food that causes some of the symptomslisted We have included this in the prerequisite programs point of the HACCP Starbecause allergies are a growing concern in the effort to serve safe food

If you are someone who has had an allergic reaction to food you can understandhow important it is to know what is in the foods you your family friends neigh-bors fellow employees and customers are consuming

The first step is to be aware of the most common allergens Although there areothers the most common known as Major Food Allergens or the ldquoBig 8rdquo are

Shellfish (crab lobster or shrimp)

Fish (bass flounder or cod)

Peanuts

Tree nuts (chestnuts pistachios Brazil nuts etc)

Milk

Eggs

Soytofu

Wheat

Other allergens associated with food preparation are

MSG or monosodium glutamate (used as a food additiveflavorenhancer)

Sulfites or sulfur dioxide (used as a vegetable freshenerpotato whiten-ing agent)

Latex (for example latex residue can be transferred from the latex glovesto foods such as tomatoes before it is served) It is recommended thatemployees not wear latex gloves when touching food

Some allergens cause reactions that range from mild to severe enough to causedeath You should take the following steps to ensure your customers avoid eating

ch01_4597qxd 1262005 124 PM Page 9

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 21: The HACCP Food Safety Employee Manual 0471781827

10 HACCP Star Point 1

STAR KNOWLEDGE

How well do you understand foodborne illnesses and food allergens Answer the followingquestions

1 If you have been diagnosed with or come in contact with someone who has Hepatitis A whatshould you do

2 Name the ldquoBIG 5rdquo foodborne illnesses

3 How would you handle a customer who tells you they are allergic to walnuts but wants to order theChicken Salad that has toasted walnuts in it

foods to which they are allergic First think about how you would like to be treatedif you were the customer with a food allergy Then consider the following steps

1 Ask the customer if she has any food allergies

2 Know your companyrsquos SOP What should you do if your customer indicatesshe has a food allergy

3 Know your menu Describe all ingredients and the preparation of foods youare serving to anyone who asks even if it is a ldquosecret reciperdquo

4 Be honest It is OK to say ldquoI donrsquot knowrdquo Immediately ask your manager toassist you

5 Be careful Make sure your customer is not allergic to anything in the foodyou are serving You should also make certain that she is not allergic toanything with which the food has come into contact (SOP Prevent Cross-Contamination)

6 Be thoughtful and concerned but never tell a customer you are sorry hehas an allergy to certain foods because no one is at fault for having theallergy

7 Manage allergens by limiting the contact of food for any allergic customerIt is best if only 1 person handles the customerrsquos entire food preparationand service Even utensils and plates can cause cross-contamination ofallergens to several surfaces

ch01_4597qxd 1262005 124 PM Page 10

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 22: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 11

INTERNATIONAL FOOD SAFETY ICONSWe all know what the blue handicapped parking sign means when we drive

around a parking lot Signs with simple pictures tell us when it is safe to cross thestreet when to check the oil in our car and how to get to the airport With the samepurpose in mind International Food Safety Icons help to make food safety easierfor everyone to understand and help you to remember basic food safety rules andprocedures for food preparation Throughout this section you will see the variousInternational Food Safety Icons which will help you succeed in becoming a HACCPSuperstar The International Food Safety Icons provide a visual definition andreminder of the Standard Operating Procedures for the foodservice industry A teamof managers and supervisors has established prerequisite programs policiesprocedures and recipes that must be followed The International Food Safety Iconsmake it easy to understand remember and reinforce these procedures

The Food Safety Match Game gives you an overview of the Standard OperatingProcedures used in most foodservices Check your knowledge of food safety bymatching the International Food Safety Icons with the associated rule Earn a starfor each correct answer Select the food safety rule that best fits the food safetysymbol

We are confident that if you follow the Standard Operating Procedures in thismanual you will learn the basics of food safety Learning food safety basics is thefirst step toward creating an effective HACCP plan You must know the properways to cook and prepare food before you can determine what mistakes are beingmade in preparing the food Your trainer will help you in this process

ch01_4597qxd 1262005 124 PM Page 11

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

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ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

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ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

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ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

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ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 23: The HACCP Food Safety Employee Manual 0471781827

12 HACCP Star Point 1

1 2 3

4 5 6

7 8 9

10 11

A Do Not Work If Ill

B Cold HoldingmdashHold cold foods below 41degF(5degC)

C No Bare-Hand ContactmdashDonrsquot handle foodwith bare hands

D Hot HoldingmdashHold hot foods above 135degF(572degC)

E Temperature Danger Zone (TDZ)mdash41degF to135degF (5degC to 572degC)

F Potentially Hazardous FoodsmdashTimeTemperature Control for Safety Food(PHFTCS)

G Cook All Foods Thoroughly

H Wash Your Hands

I Do Not Cross-ContaminatemdashFrom raw toready-to-eat or cooked foods

J Wash Rinse Sanitize

K Cooling Food

FOOD SAFETY MATCH GAME

How many points did you earn _______

If you scored 10ndash11 pointsmdashCongratulations You are a Food Safety Superstar

If you scored 8ndash9 pointsmdashGood job You have a basic understanding of food safety

If you scored 5ndash7 pointsmdashThe time for review is now What a great opportunity to fine-tune your food safety skills

If you scored 0ndash4 pointsmdashEveryone needs to start somewhere

ch01_4597qxd 1262005 124 PM Page 12

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 24: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 13

bull Hand sanitizers should onlybe used on clean hands

bull Hand sanitizers are not asubstitute for hand washing

bull Use only sanitizersapproved by the FDA

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETYAs an employee some of your personal responsibilities related to providing

safe food are staying home when sick washing your hands using gloves properlyand following a food-safe dress code Each icon represents a food safety standardoperating procedure Letrsquos look at the first International Food Safety Icon

DO NOT WORK IF ILL

If you have gastrointestinal symptoms like fever vomiting diarrhea or you are illand sneezing and coughing you should not work around or near food and bev-erages If you are diagnosed with a foodborne illness it is critical that you stayhome until your physician states that you are able to work around food againPlease notify the person in chargemanager of any illnesses you may have espe-cially if you have Norovirus Hepatitis A E-Coli Salmonellosis or Shigellosis (oneof the Big 5) because these diseases must be reported to the regulatory authority

WASH YOUR HANDS

Wash your hands Wash your hands Wash your hands

Use the following hand-washing recipe

1 If the paper towel dispenser requires you to touch the handle or lever thefirst step should be to crank down the paper towel Let the paper towel hangthere Do not do this if the paper towel touches and cross contaminates withthe wall or the waste container

2 Wet your hands (100ordmF378ordmC)

3 Add soap

4 Scrub for 20 seconds

Donrsquot forget your nails thumbs and between your fingers

Some regulators require nailbrushes

5 Rinse

6 Dry with a paper towel

Put on gloves if touching ready-to-eat food

If exiting a restroom wash your hands again when you reenter thekitchen because your hands could have been contaminated when youexited the bathroom and touched the handle to the door

When Do You Wash Your Hands and Change Your Gloves

After going to the bathroom

Before and after food preparation

After touching your hair face or any other body parts

After scratching your scalp

After rubbing your ear

After touching a pimple

After wiping your nose and using a tissue

ch01_4597qxd 1262005 124 PM Page 13

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 25: The HACCP Food Safety Employee Manual 0471781827

14 HACCP Star Point 1

Copyright copy International Association for Food Protection

After sneezing and coughing into your hand

After drinking eating or smoking

After touching your apron or uniform

After touching the telephone or door handle

After touching raw food and before touching ready-to-eat products

After cleaning and handling all chemicals

After taking out the trash

After touching any non-food-contact surfaces

Every 4 hours during constant use

After touching a pen

After handling money

After receiving deliveries

Before starting your shift

NO BARE-HAND CONTACT

You must not touch Ready-To-Eat (RTE) foods with bare hands RTE foods arefoods that are exactly that ldquoready to eatrdquo like bread pickles lunchmeats andcheese These foods should be handled with gloves deli paper tongs and utensils

One in three people do not wash their hands after using the bathroom but gloveshelp stop the fecaloral route of contamination This is why there is no bare-handcontact with RTE food

DO NOT CROSS-CONTAMINATE

Between Raw and RTE or Cooked Foods

Raw food is food that needs to be cooked before eaten like raw meat and eggsAs mentioned ready-to-eat food is food that doesnrsquot need to be cooked and isready to be eaten like a sub roll or lettuce Cooked food is food that has beenproperly cooked by reaching a specific temperature for an appropriate amount oftime like a cooked hamburger Once food has been properly cooked it is nowconsidered ready-to-eat food

Food Contact Surfaces

Cross-contamination occurs when raw food touches or shares contact with ready-to-eat andor cooked foods If you touch the walk-in (refrigeratorcooler) doorhandle or a pen or the telephone and then make a sandwich this is cross-contamination Cross-contamination is using the same knife to cut both chickenand rolls If chicken is stored in the refrigerator above lettuce and the chicken dripsonto the lettuce this is cross-contamination Once food has been properlycooked it is now considered a ready-to-eat food

To avoid cross-contamination

Properly store raw food below ready-to-eat food (chicken below lettuce)

Never mix food products when restocking

Properly clean and sanitize utensils equipment and surfaces

Clean and sanitize work areas when changing from raw food preparationto RTE food preparation

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 14

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 26: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 15

Between Tasks

It is critical to change gloves wash hands and use clean and sanitized utensilscutting boards and work surfaces between tasks to prevent contamination Hereare some ways to place a barrier between you and the cross-contamination Usedifferent-colored gloves for different jobs This system makes it easy to separatefood-handling jobs from non-food-handling jobs Ask your manager if your companyhas a SOP for gloves Here are some examples of color-coding gloves

Use clear gloves for food preparation

Use blue gloves for fish

Use yellow gloves for poultry

Use red gloves for beef

Use purple gloves for cleaning and for non-food-contact surfaces

Designate different cloths and containers and code them to separate food andnon-food contact surfaces For example

Use a white cloth for food-contact surfaces

Use a blue cloth for non-food-contact surfaces

Use a green container for cleaning (water and soap)

Use a red container for sanitizing (water and sanitizer)

Use color-coded cutting boards knives containers and gloves

Violating the Dress Code

Follow these rules to avoid violating the dress code

Cover all cuts and burns with a bandage and a glove

Wear your hat or proper hair restraint

Wear a neat and clean uniform and apron

Wear clean closed-toe shoes with rubber soles

Take a bath or shower every day

Always have clean and neat hair

Properly groom fingernails and hands

Do not wear nail polish or false nails

Do not wear rings necklaces watches bracelets dangly or hoop ear-rings or facial piercings According to the 2005 FDA Model Food Codethe only exception is a plain wedding band A medical alert necklace canbe tucked under the shirt or a medical alert ankle bracelet can be worn

Do not chew gum

Only eat drink and smoke in designated areas

Do not touch your hair your face or any body parts when handling orserving food

Remove aprons before leaving the food preparation areas

Wear a clean apron and uniform at all times

Never take your apron into the bathroom

ch01_4597qxd 1262005 124 PM Page 15

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 27: The HACCP Food Safety Employee Manual 0471781827

Sampling Food

Cross-contamination can occur when sampling food at your workstation Youshould never eat at your workstation unless you are taste-testing food you arepreparing Here are some proper ways to sample food

Use a single-use spoon Do not double dip Single-use means exactlythatmdashonly one taste per single-use spoon Or take a small dish ladle asmall portion of the food into the small dish Put down the ladle Stepaway from the pan or pot Then taste the food Place items in the dirtydish area of your establishment

Always wash your hands and return to work

POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OFFOOD (PHFTCS)

A potentially hazardous food (PHF) is any food capable of allowing germs togrow These PHFs have the potential to cause foodborne illness outbreaks Theyare usually moist (like watermelon) have lots of protein (like dairy and meat) anddonrsquot have very high or very low acidity (neutral acidity) Adding lemon juice orvinegar to foods slows the growth of the germs

Potentially hazardous food requires strict time and temperature controls to staysafe Food has been timendashtemperature abused anytime it has been in the tem-perature danger zone (TDZ) (41degFndash135degF or 5degCndash572degC) for too long (4 hours)(More on the TDZ in the next section) Potentially hazardous foods must be checkedoften to make sure that they stay safe The caution sign includes a clock and ther-mometer to stress the importance of monitoring time and temperature The clock isthe reminder to check food at regular time intervals (like every 2 or 4 hours) The ther-mometer required must be properly calibrated cleaned and sanitized

Here is a list of potentially hazardous foods (PHFs)

Milk and milk products

Shell eggs

Fish

Poultry

Shellfish and crustaceans

Meats beef pork and lamb

Baked or boiled potatoes

Cooked rice beans and heat-treated plant food (cooked vegetables)

Garlic-and-oil mixtures

Sproutssprout seeds

Sliced melons

Tofu and other soy-protein food

Synthetic ingredients (ie soy in meat alternatives)

The timetemperature control for safety of food (TCS) looks at the charac-teristics like acidity and water activity of the food

16 HACCP Star Point 1

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 16

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

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Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 28: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 17

Copyright copy International Association for Food Protection

TEMPERATURE DANGER ZONE (TDZ)

BE SAFEmdashMONITOR TIME AND TEMPERATURE

This symbol means no food should stay between 41degF and 135degF (5degCndash572degC)as this is the temperature danger zone (TDZ) Germs and bacteria grow andmultiply very very fast in this zone If a (PHFTCS) stays in the temperature dangerzone of (41degFndash135degF or 5degCndash572degC) for more than 4 hours it is timendashtemperatureabused and can make people very sick In the 2005 FDA Model Food Code thereis a new exception to the 4-hour rule If the internal temperature of food is 41degF(5degC) or lower once it is removed from TC cold holding it can remain out of TC forup to 6 hours as long as the internal product temp does not go above 70degF(211degC) That is why cold food must be cold at 41degF (5degC) or lower and hot foodmust be hot at 135degF (572degC) or above It is important to practice temperaturecontrol (TC) to make sure foods are not timendashtemperature abused

Since foods should not sit on the counter for more than 4 accumulated hours youshould put food away as soon as possible Check holding units (ovensrefrigera-torsfreezerswarmersserving lines) at regular intervals to ensure food safety Forexample if the steam table was accidentally unplugged it could result in the foodtemperature dropping to 120degF (489degC) If the last time you took the temperatureof the food on the table was less than 4 hours ago you can reheat the food to165degF (739degC) for 15 seconds within 2 hours and continue to serve the productBut if the last time you took the temperature was more than 4 hours ago then youMUST discard all the foods that are timendashtemperature abused This unsafe food canmake anyone who eats it sick

Something to think about

What is the temperature of a healthy human _____

If you answered 986degF (37degC) you are correct But 986degF (37degC) is right in themiddle of the temperature danger zone Our bodies are ideal for germs becausewe are in the TDZ Germs love people Those germs will be transferred to peoplersquosfood if you are not careful That is why controlling time and temperature andmaintaining good personal hygiene are keys to the success of food safety

Checking Food Temperatures with Calibrated Thermometers

What is the point of checking temperatures if you have no clue whether the ther-mometer is working properly Calibrated thermometers ensure temperatures offood are correct There are many types of thermometers bimetallic thermocoupleinfrared with probe digital and disposable temperature indicators to name a fewThermometers must be checked every shift for correct calibration The simple actof dropping a thermometer on the floor or banging the thermometer against a preptable can knock the thermometer out of calibration All food must be checked witha properly calibrated thermometer Follow these steps to calibrate a bimetallicstemmed thermometer the most commonly used thermometer in the foodserviceindustry

ch01_4597qxd 1262005 124 PM Page 17

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 29: The HACCP Food Safety Employee Manual 0471781827

18 HACCP Star Point 1

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

Step 1 Step 2 Step 3

0

20

40

6080

220

200

180

160

140

100 120

BOILING-POINT METHOD

S t e p 1Fill the containerwith crushed ice andwater

S t e p 2Submerge sensingarea of stem or probefor 30 seconds

S t e p 3Hold calibration nutand rotatethermometer headuntil it reads 32degF(0degC)

S t e p 1Bring a deep pan ofwater to a boil

S t e p 2Submerge sensingarea of stem orprobe for 30 seconds

S t e p 3Hold calibration nutand rotate ther-mometer head untilit reads 212ordmF(100ordmC)

Thermometer TipsStore several cleanthermometers in aconvenient locationin a container filledwith sanitizer solu-tion The sanitizersolution should bechecked every 4hours to verifyconcentration

ICE-POINT METHOD

ch01_4597qxd 1262005 124 PM Page 18

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 30: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 19

Properly Thaw Foods

Often we need to thaw food prior to starting the cooking process How manytimes have you thought ldquoWe can pull the turkeys from the freezer and let them siton the work table to thawrdquo Sitting frozen food on the counter to thaw is not a safefood-handling practice Food needs to safely move through the TDZ as it thaws

There are four safe methods for thawing food

Method 1 Thaw in the refrigerator As foods thaw they may produceextra liquid Be sure to place PHFTCS in a refrigerator in a panor on a tray to avoid cross-contamination

Method 2 Thaw in running water Foods to be thawed under runningwater must be placed in a sink with running water at 70degF(211degC) or cooler The sink must be open to allow the water topush the microorganisms off the food and flow down the drainDo not allow the sink to fill with water

Method 3 Cooking Frozen food can be thawed by following the cookingdirections for the product Frozen food may take longer to cookdepending on the size and type of product

Method 4 Microwave Food can be thawed using the microwave if it willthen be immediately cooked When thawing food in themicrowave remember that there will be uneven thawing andsome of the food may have started to cook taking some of thefood into the TDZ This is why you must finish the cookingprocess immediately after microwave thawing

COOK ALL FOODS THOROUGHLY

Each PHFTCS food has a minimum internal cooking temperature that must bereached and held for 15 seconds to ensure that it is safe and does not make any-one sick

Minimum Internal Cooking Temperatures

Here are some minimum internal cooking temperatures to keep in mind whenpreparing food

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

When combining already cooked and raw PHFTCS products(casseroles)

Foods cooked in a microwave then let sit for 2 minutes

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

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ch01_4597qxd 1262005 124 PM Page 19

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 31: The HACCP Food Safety Employee Manual 0471781827

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145degF for 4 minutes

135degF (572degC) or 15 Seconds

Cook RTE foods

Commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

COLD HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

In cold holdingself-service bars (refrigeration) store all cold foodbelow 41degF (5degC)

Check temperatures of the food in cold holding a minimum of every 4hours with a calibrated cleaned and sanitized thermometer

Always keep food out of the TDZ

HOT HOLDING

Be SafemdashMonitor Time and Temperature

Here are time and temperature food safety rules

Store all hot food in hot holdingself-service bars (steam table) above135degF (572degC)

Check temperatures of the food in hot holding a minimum of every 4hours with a calibrated clean and sanitized thermometer

Always keep food out of the TDZ

COOLING FOOD

Two-stage cooling allows PHFTCS food to be in the temperature danger zone formore than 4 hours only if these strict guidelines are followed Cool hot food from135degF to 70degF (572degC to 211degC) within 2 hours you then have an additional 4hours to go from 70degF to 41degF (211degC to 5degC) or lower for a maximum total cooltime of 6 hours Note If the food does not reach 70degF (211degC) within 2 hours youmust immediately reheat to 165degF (739degC) and then begin the cooling processover again from that point

Cool food as quickly as possible Keep in mind 6 hours is the maximum amountof time but only if you reach 70degF (211degC) within 2 hours This additional 4 hoursis because the food moves through the most dangerous section of the TDZ withinthe first two hours Less time is better Your goal when cooling food is to movefood as quickly as possible through the TDZ

20 HACCP Star Point 1

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 20

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 32: The HACCP Food Safety Employee Manual 0471781827

Proper ways to cool food quickly

Use a clean and sanitized ice paddle

Stir food to release the heat

Use an ice bath

Add ice as an ingredient

Use a quick-chill unit such as a blast chiller

Separate food into smaller portions or thinner pieces

Once food has cooled to 70degF (211degC) it should be placed in the refrigeratoras follows

Place food in shallow stainless steel pans (no more than 4 inches deep)

Make sure pan cover is loose to allow the heat to escape

Place pans on top shelves in refrigeration units

Position pans so air circulates around them (Be cautious not to overloadrefrigerator tray racks)

Monitor food to ensure cooling to 41degF (5degC) or lower occurs as quicklyas possible so as not to exceed the two-stage cooling process

The refrigerator and freezer are not designed to cool hot food The warmest tem-perature to be placed in a refrigerator is 70degF (211degC) in a freezer 41degF (5degC) Ifhot food is placed in a refrigerator unit the refrigerator unit will work harder andwarm the other foods that were already supposed to be cold ruining both thefoods and the expensive refrigeration unit

REHEATING

The goal of reheating is to move food as quickly as possible through the TDZ It iscritical when reheating food to cook the food to a minimum of 165degF (739degC) for15 seconds within 2 hours If food takes longer then 2 hours to reheat it must bediscarded or thrown away Use steam when possible to reheat food and not dryheat Never use hot holding equipment to reheat food because the equipmentis not designed for that purpose Hot holding equipment is designed to hold thetemperature once the food is hot

WASH RINSE SANITIZE

Clean and Sanitize ldquoSparklerdquo

Follow Proper Cleaning and Sanitizing Food Safety Rules

What Is Cleaning

Cleaning is removing the dirt you can see on a surface The expectation is foreverything to ldquosparklerdquo A sparkling-clean foodservice operation impresses eachcustomer Clean all surfaces equipment and utensils every 4 hours or when theybecome soiled or no longer ldquosparklerdquo You can use detergents or solvents or scrap-ing to clean

Prerequisite Programs 21

Copyright copy International Association for Food Protection

ch01_4597qxd 1262005 124 PM Page 21

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 33: The HACCP Food Safety Employee Manual 0471781827

What Does It Mean to Sanitize

Sanitizing is reducing the unseen germs on a surface to a safe level

1 After proper cleaning sanitize all things that come in contact with foodutensils cutting boards and prep tables

2 Clean and sanitize at minimum every 4 hours

3 You can sanitize with hot water that is at least 180degF822degC (dishwashingmachines) or use a chemical sanitizer

Your manager will work with you to demonstrate the proper SOP for your food-service operation There are 3 important points to remember

Always use a sanitizer test strip when preparing a sanitizer solution

Use separate cloths for food surfaces like a prep table and non-foodsurfaces like a wall or floor

Use a designated sink system like the three-compartment sink to cleanand sanitize dishes and utensils Never clean and sanitize dishes in thehand washing or food preparation sinks Mop water can only be emptiedinto the utility sink or the toilet never in the three-compartment sink

How Do You Set Up a Three-Compartment Sink

Step 1 Clean and sanitize entire sink before starting

Step 2 Scrape and rinse dirty dishes

Step 3 Wash at 110degF (433degC) with soapy water

Step 4 Rinse at 110degF (433degC) with clear water

Step 5 Sanitize using your SOP

Step 6 Air-dry

SERVING FOOD AND OPERATING SELF-SERVICE BARS

SERVING FOOD

Can you answer YES to any of these questions

Do you stack dinner plates andor coffee cups when serving fooddrinkto customers

Are your fingers on the edge of the plate in the food

Do you serve clear tables answer the phone and cashier without wash-ing hands

Do you recycle rolls unwrapped butter uneaten garnishes (pickles) fromplates

Do you store utensils towels or your order pad in your pockets or waist-band

If you answered yes to any of these questions then the time is now to begin serv-ing food safely Donrsquot let food safety end in the kitchen You can play an importantrole in food safety Servers should never stack dinner plates and cups on top ofone another or on arms or carry too many in one hand It is a surefire way to cross-

22 HACCP Star Point 1

ch01_4597qxd 1262005 124 PM Page 22

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 34: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 23

contaminate foods Todayrsquos customer is more educated and will be more aware ofservers who bus tables and then touch plates or glasses as they deliver food with-out washing their hands between each task This same customer is also aware ofthe server who answers the phone writes down an order prepares the food ringsthe register and collects the money while wearing the same pair of gloves she worewhen going through the same routine for the three previous customers Thinkabout the serving practices that need improvement in your foodservice operation

It is very important not to reuse food like rolls unwrapped butter and uneatenpickle garnishes The safest rule to follow is that any food that leaves your foodservice or your control should never be served to a customer

You should always carry all utensils by the handle make sure all glasses are car-ried by the side and all plates from the bottom Do not store utensils and clothsin your pockets or in the waistband of your clothes

FOOD SAFETY FOR SELF-SERVICE AREAS

In order to keep food safe at self-service food bars and buffets

1 Separate raw meat fish and poultry from cooked and ready-to-eat food

2 Monitor customers for unsanitary hygiene practices such as the following

Tasting items

Handling multiple breads with their bare hands

Putting fingers directly into the food

Reusing plates and utensils instead hand out fresh plates to customers

3 Label all food items

4 Maintain proper temperatures

5 Practice First-In First-Out (FIFO) rotation of products Always use the oldestproduct first When refilling donrsquot mix the old food and new food together

FOOD SAFETY SOP STAR CONCLUSIONIf you know how to handle the following situations you will ensure that your

food is safe As mentioned foods may become unsafe accidentally because ofcross-contamination poor personal hygiene improper cleaning and sanitizingand timendashtemperature abuse Itrsquos important that you keep the food yourself otheremployees and your customers safe at all times Now that yoursquove read thischapter letrsquos see how much you know about food safety

ARE YOU A FOOD SAFETYldquoSUPERSTARrdquo

Match the following scenarios to the area(s) of concern related to the foodsafety practices listed

A Prevent cross-contamination

B Demonstrate proper personal hygiene

C Use proper cleaning and sanitizing procedures

D Monitor and take corrective action for time and temperature

ch01_4597qxd 1262005 124 PM Page 23

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 35: The HACCP Food Safety Employee Manual 0471781827

24 HACCP Star Point 1

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

A Prevent cross-contaminationB Demonstrate proper personal

hygieneC Use proper cleaning and

sanitizing proceduresD Monitor and take corrective action

for time and temperature

1 A serving utensil falls on the floor

2 An employee wore a dirty uniform to work

3 You are stocking shelves and notice the date on a carton of shell eggs is expired

4 It is 3 pm and you find a pan of sausage on the prep table left out since breakfast Breakfast ended at 11 am

5 As a coworker comes out of the bathroom you see her tying her apron

6 A customer returns a meatball sandwich because it is cold

ch01_4597qxd 1262005 124 PM Page 24

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 36: The HACCP Food Safety Employee Manual 0471781827

Prerequisite Programs 25

What do you do to correct the situationSituationscenario Identify the area(s) of concern Make it a ldquoREALrdquo solution

7 The sanitizer solution is supposed to be 200 ppm (parts per million) You see a new coworker set up the three-compartment sink but he uses too much sanitizer

8 A customer is allergic to fish The server tells the cook that her customer has a fish allergy The customer ordered a hamburger but there is only one spatula on the production line that is used for everything

9 A coworker is angry with a disgruntled customer and spits on the customerrsquos plate

10 Right before closing you are cleaning the walls in the food service area A customer rushes in and places an order

ch01_4597qxd 1262005 124 PM Page 25

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 37: The HACCP Food Safety Employee Manual 0471781827

26 HACCP Star Point 1

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch01_4597qxd 1262005 124 PM Page 26

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 38: The HACCP Food Safety Employee Manual 0471781827

In Star Point 2 we will discuss the basics of food defense We must understandwhat can go wrong and create food defense standard operating procedures toprevent problems from occurring before we can create an effective HACCP planThese prerequisite programs can then be incorporated into a HACCP plan

27

Food Defense

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

HACCP

HACCP STAR POINT 2

Star Point Actions You will learn to

Differentiate between food safety food security and food defense

Explain why food defense is so important

Apply food defense SOPs to handle different situations

Discuss your role in food defense as a responsible employee

ch02_4597qxd 1222005 347 PM Page 27

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 39: The HACCP Food Safety Employee Manual 0471781827

28 HACCP Star Point 2

INTRODUCTION TO FOOD DEFENSEWe in the food industry must concern ourselves with what the Department of

Homeland Security defines as food safety food security and food defense Actsof food terrorism have already been documented As a responsible employeeyou should educate yourself about the safety issues in your operation thefoodservice industry and the entire country We must work as a team each of usmust do our part from the farm to our table to stop any potential deliberate foodcontamination As an employee in the foodservice industry it is your responsibilityto take action

FOOD DEFENSE

Food Defense is the idea of preventing the deliberate contamination of foodThese actions are not accidental They are designed to cause harm to food orpeople

FOOD SAFETY

Food Safety involves the protection of food from accidental contamination suchas chemical biological or physical hazards

FOOD SECURITY

From an international viewpoint Food Security is the ability to ensure a 2-yearfood supply for a particular country

UNDERSTANDING FOOD DEFENSEConsider the following scenarios that could affect the safety of the food in

your establishment

You leave the kitchen door open for a long period of time

You encounter unusual behavior of a customer or a co-worker

You do not check to make sure your deliveries are safe and intact

There is no designated employee who monitors salad bars and fooddisplays

Chemicals are stored near the food in your operation

Chemicals are not properly labeled

You do not recognize the delivery person

The health inspector does not have identification

Off-duty employees are allowed in the facility

You must control these situations at all times to ensure food defense Fooddefense is very simple if you are aware and pay close attention to yoursurroundings fellow employees and customers

ch02_4597qxd 1222005 347 PM Page 28

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 40: The HACCP Food Safety Employee Manual 0471781827

Food Defense 29

EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE

UNDERSTANDING EMPLOYEE RESPONSIBILITIESCONCERNING FOOD DEFENSE

Your responsibility as an employee is to prepare serve and sell safe food This willprotect you your family your business and the foodservice industry The FDA rec-ommends you take Food Defense steps to ensure the safety of your customersyour coworkers and your country The recommendations include the following

EMPLOYEE AWARENESS SOP

Be a responsible employee Communicate any potential food defenseissues to your manager

Be aware of your surroundings and pay close attention to customersand employees who are acting unusual

Limit the amount of personal items brought into your work establishment

Be aware of who is working at a given time and where (in what area) theyare supposed to be working

Consistently monitor the salad bar and food displays

Make sure labeled chemicals are in a designated storage area

Make sure you and your coworkers are following company guidelines Ifyou have any questions or feel as though company guidelines are notbeing followed please ask your manager to assist you

Take all threats seriously even if it is a fellow coworker blowing offsteam about your manager and what he wants to do to get back at yourmanager or your company or if he is angry and wants to harm your man-ager a customer or the business

If the back door is supposed to be locked and secure make sure it is

Look at food products every day for irregularities If you use a food prod-uct and it is supposed to be green but today it is blue stop using theproduct and notify your manager immediately

If you know an employee is no longer with your company and this personenters an ldquoEmployee Onlyrdquo area notify your manager immediately

Cooperate during all investigations

Do not talk to the media refer all questions to your corporate office

If you are aware of a hoax notify your manager immediately

CUSTOMER AWARENESS SOP

Be aware of any unattended bags or briefcases that people bring intoyour operation

If a customer walks into an ldquoEmployee Onlyrdquo area of your operationask the customer politely if she needs help then notify a member ofmanagement

ch02_4597qxd 1222005 347 PM Page 29

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 41: The HACCP Food Safety Employee Manual 0471781827

VENDOR AWARENESS SOP

Check the identification of any vendor or service person that enters re-stricted areas of your operation and do not leave him unattended

Monitor all products received and look for any signs of tampering

When a vendor is making a delivery never accept items that are notlisted on your invoice If the vendor attempts to give you additional itemsnot listed notify your manager

When receiving deliveries

Step 1mdashAlways ask for identification

Step 2mdashStay with the delivery person

Step 3mdashDo not allow the person to roam freely throughout your operation

FACILITY AWARENESS SOP

Report all equipment maintenance and security issues to your manager

Document equipment maintenance and security issues

Be aware of the inside and outside of your facility including the dump-ster area and report anything out of the ordinary

HOAXES

Equally damaging are false accusations or fraudulent reports of deliberate con-tamination of food As a responsible employee you need to notify your managerif you suspect a false alarm has occurred An example of a hoax would be if Com-pany XYZ fell victim to a hoax where a customer stated that she found a horrify-ing object in her food After further investigation the horrifying object was actuallyplaced in the food by the customer as a ploy to collect a large sum of money fromthe company This hoax is damaging to the employees the company the brandand the foodservice industry Stories like this negatively affect everyone

POINTS TO REMEMBER

When it comes to Food Defense it is not a guessing game it is allabout the facts

Be aware of what to do in the case of any food defense crime orhoax and always report any potential threat to managementimmediately

Remember that doing nothing at all is still taking an action By nottaking an action you are allowing such situations to happen

30 HACCP Star Point 2

ch02_4597qxd 1222005 347 PM Page 30

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 42: The HACCP Food Safety Employee Manual 0471781827

Food Defense 31

Bob is the manager of a foodservice establishment in alarge city and he is scheduled to work the morning shift Assoon as Bobrsquos shift begins two cooks call in sick One cookwas scheduled to work the lunch shift and the other wasscheduled to unload the truck Bob calls all of the othercooks to see if they can work but no one can come in

Bob tells Bill the morning prep cook about the situationThe two of them will be the only employees working in thekitchen through lunch Bill will be responsible for unloading

the truck between making orders while Bob will run theregister and finish preparing the orders that come out of theoven

When the truck arrives both Bob and Bill are doing every-thing they can to keep up with the busy lunch rush Neitherof them has time to help unload the truck so the vendorunloads the truck alone and leaves the food on the loadingdock Two hours later Bob and Bill work together to bringthe food into the food establishment

Discussion Questions

Take time to discuss your answers

What food defense concerns did you recognize in this story

What if anything can Bob or Bill do to run a safer operation

REALITY CHECK

Read the story below and answer the questions about food defense concerns in this situation

ARE YOU A FOOD DEFENSEldquoSUPERSTARrdquo

Should you get involved if you suspect something is not quite right withyour food operation on a given day Yes or No

Should you do something about the potential problem Yes or No If youanswered no how well do you think you will sleep tonight if someonegets ill because you were scared or you ignored the situation

Doing NOTHING at all IS taking an ACTION By not taking an actionyou are allowing such situations to happen

ch02_4597qxd 1222005 347 PM Page 31

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 43: The HACCP Food Safety Employee Manual 0471781827

In the following situations what can you do to provide Food Defense for your cus-tomers your coworkers your country and the business you represent

32 HACCP Star Point 2

Situationscenario Is this a concern Yes or no What do you do

1 You see a coworker behaving in a suspicious manner The coworker has contaminated food but you donrsquot know if it was done accidentally or deliberately

2 A customer wanders into an ldquoEmployee-Onlyrdquo area

3 A fellow coworker is upset and starts talking about ways he is going to harm the manager and the company He only seems to be blowing off steam

4 A customer brings a large duffel bag into your operation

5 An ex-coworker loved by everyone wanders into the ldquoEmployee-Onlyrdquo area to say hello to everyone

6 A vendor walks through the back door with a delivery

7 A vendor is making a delivery The manager ordered seven containers of a certain food item but the vendor wants to give you an extra container

8 You walk by the food bar and see a spray bottle of glass cleaner sitting on it

ch02_4597qxd 1222005 347 PM Page 32

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 44: The HACCP Food Safety Employee Manual 0471781827

Food Defense 33

Take action Make it happen You can do it

Situationscenario Is this a concern Yes or no What do you do

9 An incident happened in your operation causing a customer to become seriously ill As you walk to your vehicle a news reporter approaches you

10 You are in the process of preparing food for the day and you pull a can off the shelf There is a small hole in the top of the can

Resources

wwwfdagovocbioterrorismbioacthtml

wwwgaogovnewitemsrc00003pdf

wwwfdagovocbioterrorismreport_adulterationhtml

wwwcfsanfdagov~dmsfoodcodehtml

wwwfdagovoratrainingorauFoodSecuritydefaulthtm

wwwfdagov

ch02_4597qxd 1222005 347 PM Page 33

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 45: The HACCP Food Safety Employee Manual 0471781827

34 HACCP Star Point 2

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch02_4597qxd 1222005 347 PM Page 34

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 46: The HACCP Food Safety Employee Manual 0471781827

In Star Point 3 we will discuss the key point of a HACCP Plan Now that we haveestablished prerequisite programs and SOPs for food safety and food defense wehave the foundation for an effective HACCP plan In addition your managerdirector should have reviewed program basics such as facility design equipmentpest control chemical control cleaning and sanitizing procedures responsibleemployee practices food specifications and food temperature control with you

35

Create a HACCP Plan

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

HACCP

HACCP STAR POINT 3

ch03_4597qxd 1222005 348 PM Page 35

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 47: The HACCP Food Safety Employee Manual 0471781827

36 HACCP Star Point 3

To begin development of a HACCP plan your HACCP team must first conduct ahazard analysis If this is your responsibility as a member of the HACCP teamthen you must identify the hazards associated with preparing food After identify-ing these hazards you must divide the establishmentrsquos menu based on how eachfood is prepared As each food is prepared you must determine what steps youneed to take in order to prepare safe food

HACCP INTRODUCTION

WHAT IS HACCP

HACCP (ldquohas-siprdquo) is a food safety system that prevents disasters such as food-borne illness outbreaks from occurring A foodborne illness occurs when you eatfood and it makes you sick An outbreak occurs when two or more people eat thesame food and get the same illness HACCP helps prevent foodborne illness out-breaks because HACCP is a proactive approach to control every step in the flow offood Simply stated the HACCP goal is to stop control and prevent food safetyproblems

HACCP is an abbreviation for Hazard Analysis and Critical Control Point HACCPis a written food safety system to enable you to serve safe food The HACCP foodsafety system has seven principles You will learn about all seven principles in thenext three Star Point sections No matter what your job description and duties areyou will benefit from understanding and knowing the HACCP system For manyoperations like food manufacturers and public school systems having a HACCPplan in place is mandated by their regulatory authority

WHY IS HACCP IMPORTANT

To understand why HACCP is so important you need to first familiarize yourselfwith the history of the HACCP program HACCP was originally designed in theearly 1960s by NASA and the Pillsbury Company for the US space program Yesthe HACCP program was actually developed by rocket scientists The reason whythey developed the program was to prevent the astronauts from getting sick inspace Can you imagine an astronaut in space who is vomiting and has diarrhea

All food has microorganisms which is why NASA needed a food safety systemthat would prevent eliminate and reduce the number of microorganisms to safelevels They needed to prevent a foodborne illness from occurring in space AfterNASA incorporated HACCP plans the military manufacturers schools and insome jurisdictions retailers have also followed suit Ask your manager if your op-

Star Point Actions You will learn to

Define HACCP

Summarize why HACCP is important

Describe the flow of food

Describe the HACCP philosophy and define your role

Practice a hazard analysis (HACCP Principle 1)

Determine critical control points (HACCP Principle 2)

ch03_4597qxd 1222005 348 PM Page 36

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 48: The HACCP Food Safety Employee Manual 0471781827

Create a HACCP Plan 37

eration is required by law to have a HACCP plan Now that we know the history ofHACCP and why it became necessary to incorporate a HACCP plan letrsquos take alook at the HACCP philosophy

THE HACCP PHILOSOPHYHACCP is internationally accepted HACCP is not a process conducted by an

individual it involves the entire team This is why you are a part of this trainingsession Your managerdirector is counting on you to do your part in preventingfoodborne illness in your food service operation and in your part of the world TheHACCP philosophy simply states that biological chemical or physical hazardsat certain points in the flow of food can be

Prevented

Removed

Reduced to safe levels

Today foods are transported around the world more than ever before As a resultmore people are handling the food products The more food products are touchedby people or machines the greater the opportunity for contamination or evenworse the greater the opportunity to spread a foodborne illness

The eating habits of people around the world have changed as well People eatmore ready-to-eat foods and enjoy more ethnic dishes and food varieties thanever before This is why we need HACCP

The CDC lists the five most common risk factors that create foodborne illness

Practicing poor personal hygiene

Improperly cooking food

Holding foods at the wrong temperatures

Using equipment that hasnrsquot been properly cleaned and sanitized

Buying food from unsafe suppliers

Letrsquos get started with Principle 1

PRINCIPLE 1 CONDUCT A HAZARDANALYSIS

A hazard analysis is the first HACCP principle in evaluating foods in youroperation This is the first step to identify any PHFTCS food used in yourestablishment The analysis looks for potential hazards that are reasonably likelyto occur in your operation A hazard analysis focuses on food safety not foodquality It is important to separate food safety from food quality Consider thefollowing A certain food might be dried out by one or more reheating steps It mayhave lost some of its appeal to a customer but it is still safe to eat

The key to a successful HACCP program is to conduct a thorough hazard analy-sis If the hazards are not correctly identified the risks to your program increasesignificantly and the program will not be effective

There are 4 primary goals in the hazard analysis

A Identify PHFTCS foods Remember not all foods are potentially haz-ardous See Star Point 1 if you need to review

PRINCIPLE 1

ch03_4597qxd 1222005 348 PM Page 37

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 49: The HACCP Food Safety Employee Manual 0471781827

B Understand the flow of food to determine where hazards may becontrolled

C Divide menu items into 3 categories by how the food is prepared

D Analyze 2 questions

ldquoWhat is the likelihood of a hazard to occur hererdquo

ldquoWhat is the risk if the hazard does occurrdquo

Letrsquos talk about each of these goals

IDENTIFY POTENTIALLY HAZARDOUS FOODmdashTIMETEMPERATURE CONTROL FOR SAFETY OF FOOD

To analyze the food in your establishment the first thing to do is to identify allPHFTCS food Using this sample menu can you identify any PHFTCS foodsRemember not all foods are potentially hazardous

38 HACCP Star Point 3

Sample Menu

StartersVegetable Tray with from-scratch buttermilk ranch dipChicken SoupBeef Chili

EntreacuteeSalmon Stuffed with CrabmeatPopcorn ShrimpHamburgerTuna Salad

Side DishesGarden Salad with homemade bleu cheese dressingCole SlawGrilled Vegetables

Star Knowledge

Identify all PHFTCS from the sample menu

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

mdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashmdashndashmdashmdashmdashmdashmdashmdashmdashmdashndash

FLOW OF FOOD

In order to determine where hazards may be controlled you need to understandthe flow of food All the food we eat goes through what we call a flow of food Allflows of food start with the purchasing of food from approved sources The foodis then received stored prepared cooked held cooled reheated and served

The flow of food is best described by looking at how you make a pot of home-made soup First you purchase the ingredients from a clean safe grocery storeYou take the food you purchased and receive the food into your home then youneed to store the food properly either in dry storage (your cabinets or pantry) orin your refrigerator and freezer Once the food is stored properly you then preparethe food (slicing vegetables portioning meats etc) After preparation the productis cooked To cook your homemade soup properly it must reach a minimum tem-perature of 165degF (739degC) Once the soup has reached 165degF (739degC) then youcan hold the soup The correct hot holding temperature for your delicious home-made soup is 135degF (572degC) The next step in the flow of food is to cool the soupfor storage in your refrigerator The proper way to cool soup is to cool it as quicklyas possible to 41degF (5degC) (follow the cooling process you learned in Star Point 1)The next day you see the soup in your refrigerator and you decide to reheat it

FLOW OF FOOD

Purchase

Receive

Store

Prepare

Cook

Hold

Cool

Reheat

Serve

ch03_4597qxd 1222005 348 PM Page 38

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 50: The HACCP Food Safety Employee Manual 0471781827

The soup must be reheated to 165degF (739degC) for 15 seconds before it is safe Thefinal step is to serve the soup and enjoy

In summary the flow of food is purchase receive store prepare cook hold coolreheat and serve HACCP helps you to ensure that at every step in the flow offood the food stays safe In our example no one got sick by eating the homemadesoup because food safety SOPs were followed in the flow of food It is necessaryfor all food establishments to set the same goalmdashto serve safe food

CHICKEN SOUP

Purchase

Receive

Store

Prepare

Cook

CoolStore (COLD)

Reheat

Hold (Hot)

Serve

Create a HACCP Plan 39

ch03_4597qxd 1222005 348 PM Page 39

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 51: The HACCP Food Safety Employee Manual 0471781827

40 HACCP Star Point 3

STAR KNOWLEDGE EXERCISEFlow of Food Activity

In this activity identify the steps in the flow of food for tuna salad and a hamburger Determine whatthe steps are and label the boxes in the correct order

TUNA SALAD HAMBURGER

Notice some recipes may have more steps than others

ch03_4597qxd 1222005 348 PM Page 40

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 52: The HACCP Food Safety Employee Manual 0471781827

DIVIDE YOUR MENU ITEMS INTO CATEGORIES

Once the flow of food is determined for your menu items you should then divideyour menu items into 1 of 3 categories by how the item is prepared There are threeways to divide the menu No Cook Same Day and Complex

A SimpleNo-Cook Recipe means exactly that there is no cooking involved Forexample when tuna salad is prepared a can or bag of tuna is opened drained ofthe juice placed in a bowl mayonnaise and seasonings are added it is mixedwell chilled and served

Other foods your HACCP plan might identify as simpleno-cook recipes include

Tuna salad

Cole slaw

Vegetable tray

A Same-Day Recipe means a food product is prepared for same-day service orhas some same-day cooking involved For example a hamburger requires thatyou take the frozen hamburger patty from the freezer place the hamburger on thegrill cook the hamburger to 155degF (683degC) for 15 seconds place the cooked ham-burger on a bun and serve Other foods your HACCP plan might identify as same-day recipes include

Hamburgers

Popcorn shrimp

Grilled vegetables

A Complex Recipe calls for a food to be prepared cooled stored and then re-heated If a food moves through the temperature danger zone more than twotimes it is considered a complex recipe The homemade soup described earlier isan example of a complex recipe

When using a complex recipe you must

1 Determine the potential for microorganisms to

a Survive a heat process (cooking or reheating)

b Multiply at room temperature and during hot and cold holding

2 Find sources and specific points of contamination that are not covered inthe food safety and food defense standard operating procedures

Other foods your HACCP plan might identify as complex recipes include

Soup

Chili

Salmon stuffed with crabmeat

Analyze 2 Questions

What is the likelihood of a hazard occurring

Most hazards are biological (bacteria viruses and parasites) Other hazards mightbe chemical (cleaning products sanitizers and pesticides) or physical (metalshavings foreign objects and hair) In the tuna salad hamburger and chickensoup what is the likelihood for this to occur What are the chances these hazardscould contaminate the food

Create a HACCP Plan 41

ch03_4597qxd 1222005 348 PM Page 41

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 53: The HACCP Food Safety Employee Manual 0471781827

42 HACCP Star Point 3

What is the risk if the hazard does occur

If there is a high risk of contamination does it lead to an unacceptable health riskAn unacceptable health risk can lead to injury illness or death Or is the risk ofcontamination low to mean an acceptable health risk Acceptable risks are thosethat present little or no chance of injury illness or death Experts use scientificdata to determine if the risk is high or low in each hazard that is analyzed

The reason why biological chemical and physical hazards must be identified andrated for risk is to determine whether a preventive measure is needed In thechicken soup example the biological hazard is salmonella (highly contagious) andcampylobacter The preventive measure is to cook the chicken to 165degF (739degC)for 15 seconds to kill the salmonella and campylobacter on the chicken By doingthis the hazard is prevented eliminated and reduced to safe levels As you cansee this is why a Hazard Analysis is so important in a HACCP plan Once you haveconducted the hazard analysis you are ready to move to HACCP principle 2identifying the critical control points

PRINCIPLE 2 DETERMINE CRITICALCONTROL POINTSHACCP Principle 2 is to determine critical control points by first identifying all

the standard control points in the flow of food This helps you to identify whichpoint(s) are more critical than others If this critical step is not controlled thenpeople can get a foodborne illness Before determining control points and criticalcontrol points you need a clear understanding of what they are

1 Control Point (CP)mdashThis is any point step or procedure at which biologi-cal physical or chemical factors can be controlled If loss of control occursat this point and there is only a minor chance of contamination and there isnot an unacceptable health risk then the control point is not critical

2 Critical Control Point (CCP)mdashThis is an essential step in the product-handling process where a food safety hazard can be prevented eliminatedor reduced to acceptable levels A critical control point is one of the lastchances you have to be sure the food will be safe when you serve it It is theldquocriticalrdquo step that prevents or slows microbial growth such as proper cook-ing cooling or hotcold holding Every operation is different so critical con-trol points will vary from operation to another While not every step in theflow of food will be a CCP there will be a CCP in at least one or more stepswhenever a potentially hazardous food is in the recipe Loss of controllingthe hazards at this point could lead to an unacceptable health risk and thatis why it is critical

CRITICAL CONTROL POINT GUIDELINES

To identify critical control points ask the following important questions If you cananswer yes to all these points at any stage in the preparation process you haveidentified key critical control points

Can the food you are preparing become contaminated

Can contaminants multiply

PRINCIPLE 2

ch03_4597qxd 1222005 348 PM Page 42

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 54: The HACCP Food Safety Employee Manual 0471781827

FOOD FLOW CHART EXAMPLE

Tuna Salad

Purchase

Receive

Store

Prepare

Hold

Serve

Can contaminants survive

Can you take corrective action(s) to prevent this hazard

Is this the last chance you have to prevent eliminate or reduce hazardsbefore you serve it to a customer

In order to identify the critical control points of a food item we must first identifythe control points then determine the most important step(s) that will preventeliminate or reduce the harmful microorganisms to a safe level

Create a HACCP Plan 43

CP

CP

CP

CP

CCP

ch03_4597qxd 1222005 348 PM Page 43

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 55: The HACCP Food Safety Employee Manual 0471781827

STAR KNOWLEDGE EXERCISEIdentify Control Points and Critical Control Points

ldquoCP or CCP ActivityrdquoSame-Day RecipemdashHamburgerYou decide if each step is a control point (CP) or a critical control point (CCP)

44 HACCP Star Point 3

Hamburger

Purchase

Receive

Store

Prepare

Cook

Hold

Serve

ch03_4597qxd 1222005 348 PM Page 44

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 56: The HACCP Food Safety Employee Manual 0471781827

Create a HACCP Plan 45

Complex RecipemdashChicken Soup ldquoCP or CCP Activityrdquo

You decide if each step is a control point (CP) or a critical control point (CCP)

Chicken Soup

Purchase

Receive

Store

Prepare

Cook

CoolStore

Reheat

Hold (Hot)

Serve

ch03_4597qxd 1222005 348 PM Page 45

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 57: The HACCP Food Safety Employee Manual 0471781827

In Star Point 3 we discussed how to begin setting up a HACCP plan and how toidentify the hazards associated with preparing food After learning how to identifythese hazards we learned to divide a menu into simple same-day and complexrecipes This then laid the foundation for the flow of food control points and crit-ical control points that we identified in the last exercise Test your Star Knowledgeby answering the questions in this exercise

46 HACCP Star Point 3

STAR KNOWLEDGE EXERCISE

1 A step in the food flow process where a hazard can be controlled is called

a A Critical Control Pointb HACCPc A Control Pointd Temperature Danger Zone

2 HACCP stands for

a Hazard Associated with Cooking Chicken Productsb Hazard Analysis Critical Control Pointc Hazard Analysis Control Critical Points

3 HACCP focuses on

a Food qualityb Food safetyc Both A and Bd Neither A nor B

4 A Critical Control Point is

a a point where you check invoicesb one of the last steps where you can control prevent or eliminate a food safety hazardc the point where food is cooled and then reheated

5 Which of the following is NOT a PHF

a Foil-Wrapped Baked Potatob Chocolate Chip Cookiec Chicken Noodle Soupd Cut Watermelon

ch03_4597qxd 1222005 348 PM Page 46

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 58: The HACCP Food Safety Employee Manual 0471781827

Create a HACCP Plan 47

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

You are making good progress

ch03_4597qxd 1222005 348 PM Page 47

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 59: The HACCP Food Safety Employee Manual 0471781827

ch03_4597qxd 1222005 348 PM Page 48

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 60: The HACCP Food Safety Employee Manual 0471781827

In Star Point 4 we will discuss minimum and maximum times and temperaturesfor the critical control points covered in the previous chapter This is the most im-portant Star Point because this is where you ldquowork the planrdquo through monitoringtimes and temperatures and taking the appropriate corrective actions to keepfood safe

49

Work the Plan

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

Complete

HACCP

HACCP STAR POINT 4

ch04_4597qxd 1222005 349 PM Page 49

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 61: The HACCP Food Safety Employee Manual 0471781827

50 HACCP Star Point 4

PRINCIPLE 3 ESTABLISH CRITICAL LIMITSNow that we have completed the hazard analysis and identified control points

and critical control points the next step is to look at critical limits A critical limitis the scientific measurement that must be met for each critical control point Acritical limit is like a traffic speed limit on a major highway There is always amaximum speed If you exceed the maximum speed and get stopped you receivea ticket Critical limits are the same in food preparation if you donrsquot cook the foodto a specific temperature people may be stopped with a foodborne illness

A critical limit must be scientific measurable and specific and it must clearly in-dicate what needs to be done For example if a recipe for baked chicken saysldquocook until donerdquo or ldquocook until juices run clearrdquo is the product really safe to eatThe correct critical limit should be ldquocook to an internal temperature of 165degF(739degC) for 15 secondsrdquo Why Scientific data from the US Food and Drug Ad-ministration Model Food Code provides us with documentation that proves ourcustomers wonrsquot get sick if chicken is cooked to the designated temperature

What can be measured Definitely time and temperature Each PHFTCS food hasa minimum internal cooking temperature that must be reached and held for 15seconds to ensure that it is safe and does not make anyone sick

Here is a familiar list of critical limits to help reinforce the important minimumtimes and temperatures needed to destroy the pathogens on food and controlfoodborne illness outbreaks Other critical limits depending on your operationcould be humidity water activity (moisture content) and acidity

Minimum Temperatures

165degF (739degC) for 15 Seconds

Reheat all leftover foods

Cook all poultry

Cook all stuffed products including pasta

Foods cooked in a microwave then let sit for 2 minutes

When combining already cooked and raw PHFTCS products(casseroles)

155degF (683degC) for 15 Seconds

Cook all ground fish beef and pork

Cook all flavor-injected meats

Cook all eggs for hot holding and later service (buffet service)

PRINCIPLE 3

Star Point Actions You will learn to

Establish critical limits (HACCP Principle 3)

Define monitoring procedures (HACCP Principle 4)

Determine corrective action (HACCP Principle 5)

ch04_4597qxd 1222005 349 PM Page 50

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 62: The HACCP Food Safety Employee Manual 0471781827

Work the Plan 51

STAR KNOWLEDGE CRITICAL LIMIT EXERCISE

Complete the critical limit exercise in the space provided

1 If holding is the CCP for tuna salad what is the critical limit _________________________________________

2 If cooking is the CCP for a hamburger what is the critical limit_______________________________________

3 If holding is the CCP for a hamburger what is the critical limit _______________________________________

4 If cooking is the CCP for chicken soup what is the critical limit ______________________________________

5 If reheating is the CCP for chicken soup what is the critical limit_____________________________________

6 If cooling is the CCP for chicken soup what is the critical limit_______________________________________

7 If holding is the CCP for chicken soup what is the critical limit ______________________________________

8 If storage is the CCP for ice cream what is the critical limit__________________________________________

9 If cooking in the microwave is the CCP for fish what is the critical limit _______________________________

10 If cooking is the CCP for a pork roast what is the critical limit _______________________________________

145degF (628degC) for 15 Seconds

Cook all fish and shellfish

Cook all chopssteaks of veal beef pork and lamb

Cook fresh eggs and egg products for immediate service

Cook roasts to 145 degF for 4 minutes

135degF (572degC) or 15 Seconds

RTE foods

Fully cooked commercially processed products

Cook or hold vegetables and fruits

Hot holding for all PHFTCS

PRINCIPLE 4 ESTABLISH MONITORINGPROCEDURES

Monitoring procedures ensure that we are correctly meeting critical limits for theCCPs This is the foundation for HACCP Principle 4 If we do not regularly check theCCPs our HACCP plan can easily fall apart Monitoring enables the manager todetermine if the team is doing its part to keep food safe Monitoring also helps toidentify if there are equipment problems product concerns or refrigeration issuesThis is by far the area in which you can shine the most as a HACCP team membermdashyou make the difference in terms of whether or not your operation is serving safefood

PRINCIPLE 4

ch04_4597qxd 1222005 349 PM Page 51

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 63: The HACCP Food Safety Employee Manual 0471781827

HOW TO MONITOR

Your manager has established monitoring procedures for a successful monitoringprogram It is important to know your role and the roles of other team members

Who will monitor the CCP(s)

What equipment and materials are needed

Are you following SOPs

When should monitoring take place

How often should monitoring take place

How will the CCP(s) be monitored

There are two kinds of monitoring

Continuous

Noncontinuous

Continuous monitoring is a constant monitoring of a CCP This is done withbuilt-in measuring equipment that records time and temperatures Computerizedequipment systems are an example of continuous monitoring

Noncontinuous monitoring is primarily what the majority of foodservice opera-tions use This monitoring occurs at scheduled intervals An example of noncon-tinuous monitoring is using a properly calibrated bimetallic thermometer tomeasure the temperature of chicken soup every 2 hours

BE A MONITORING STAR

Request to be trained on monitoring procedures

Know how to use monitoring tools thermometers and so on

Know the proper temperatures

Know other critical limits

Record monitoring results in logs

Perform monitoring tasks for example every 2 hours or every 4 hours

USE MONITORING FORMS

In the HACCP system proper documentation must be kept throughout the opera-tional food flow Effectively using monitoring forms at receiving preparation cook-ing cooling reheating and storage stages provide a product history This verifiesthat a product meets standards or indicates when adjustments to the system areneeded It also ensures that you have done all you can do to keep the food safe ifa foodborne illness outbreak occurs These records become your documentation tothe Department of Health the media and local county state and federal food in-spectors

Equipment temperatures during meal preparation and service should be moni-tored at least every 4 hours this includes all refrigeration cooking and holdingequipment If necessary adjust the equipment thermostats so products meet therequired temperature standards

52 HACCP Star Point 4

ch04_4597qxd 1222005 349 PM Page 52

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 64: The HACCP Food Safety Employee Manual 0471781827

Other types of documentation include standard operating procedures sanitationpractices employee practices and employee training This may be an informal no-tation of observations concerning what is working well and what is not workingwell This documentation identifies practices and procedures that may have to bemodified and may indicate a need for additional employee training

Work the Plan 53

THERMOMETER CALIBRATION LOG (ONCE PER SHIFT)

DATE EMPLOYEE DATE EMPLOYEE DATE EMPLOYEE

6 AM

2 PM

10 PM

MGR

Monitoring (Sample SOP)

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification before ac-cepting delivery If the driverrsquos name is different than what is indicated on the delivery sched-ule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermometerinto the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary to takethe internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Examples of Monitoring Forms

ch04_4597qxd 1222005 349 PM Page 53

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 65: The HACCP Food Safety Employee Manual 0471781827

COOLING LOG EMPLOYEE MANAGER

degFTIME degF TIME Must TIME degF TIME degF TIME degF TIMEAfter After After 70degF After After After After After After After

DATE FOOD 1 Hour 1 Hour 2 Hours 211degC 3 Hours 3 Hours 4 Hours 4 Hours 5 Hours 5 Hours 6 Hours degF

54 HACCP Star Point 4

HOLDING LOG DATE EMPLOYEE MANAGER

FOOD 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM 6 AM 10 AM 2 PM 6 PM 10 PM 2 AM

COOKING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ordmF ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 54

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 66: The HACCP Food Safety Employee Manual 0471781827

Work the Plan 55

STAR KNOWLEDGE MONITORING EXERCISE

What types of monitoring logs and food safety equipment would you need to have in place for thefollowing foods Place the appropriate letter(s) of the monitoring log(s) and equipment for each fooditem Are there any additional logs or food safety equipment that you would use in your food serviceoperation

Monitoring Logs

A Receiving log or invoice (indicating temperature of frozen andor refrigerated food as received)

B Freezer temperature log

C Refrigerator temperature log

D Dry storage temperature log

E Preparation temperature log

F Cooling log

G Reheating log

H Serving line temperature log

Equipment

I Calibrated thermometers

J Cold holding equipment

K Cold serving equipment

L Hot holding equipment

M Hot serving equipment

N Equipment to quickly cool soupmdashice bath ice paddle pans to reduce product for quicker cooling or a BlastChiller

1 Tuna salad prepared on-site to be served that day

2 Hamburger to be cooked on-site and served that day

3 Chicken soup prepared on-site to be served the next day

ch04_4597qxd 1222005 349 PM Page 55

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 67: The HACCP Food Safety Employee Manual 0471781827

56 HACCP Star Point 4

Sample SOP Receiving Deliveries

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deterioration ndash swollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of safe temperature zone or deemed unacceptable by the establishedrejection policy

PRINCIPLE 5 IDENTIFY CORRECTIVEACTIONSNow that the minimum and maximum limits have been identified and met

through your monitoring we can identify the corrective actions necessary to fix thedeficiencies The corrective actions are predetermined steps that you automaticallytake if the critical limits are not being met This is also HACCP Principle 5 Followingare examples of corrective actions

Reject a product that does not meet purchasing or receiving specifications

Reject a product that does not come from a reputable source

Fix thermometers on refrigerators freezers ovens hot holding carts andso on

Discard unsafe food products

Discard food if cross-contamination occurs especially if there is nocooking step

Continue cooking food until it reaches correct temperature

Reheat food to 165degF (739degC) for 15 seconds within 2 hours

Change methods of food handling

Train staff to calibrate thermometers and take temperatures properly

Document Write Everything Down

Donrsquot forget to record what you have done to correct the problems you have ob-served when monitoring This practice is important and helpful if a customer isstricken with a foodborne illness You will need these documents as evidence of im-plementation of your HACCP system

In Star Point 4 we discussed why this is the most important Star Point for youThis is where you make the greatest difference You do that by ldquoworking theplanrdquomdashby monitoring identifying and facilitating corrective actions that in turnmake food safe

PRINCIPLE 5

ch04_4597qxd 1222005 349 PM Page 56

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 68: The HACCP Food Safety Employee Manual 0471781827

Work the Plan 57

RECEIVING LOG DATE

FOOD PRODUCT CORRECTIVE EMPLOYEE MANAGERTIME TEMP DESCRIPTION PRODUCT CODE ACTION TAKEN INITIALS INITIALS

Sample Corrective Action Logs

COOLINGmdashCORRECTIVE ACTION LOG

FOOD TEMPERATURE CORRECTIVEDATE PRODUCT TIME MUST 70degF (211degC)ndash2 HOURS ACTION TAKEN

MUST 41degF (5degC)ndash6 HOURS bull MUST REHEAT EMPLOYEE MANAGERbull MUST DISCARD INITIALS INITIALS

REFRIGERATION LOG

CORRECTIVE EMPLOYEE MANAGERDATE TIME TYPE OF UNIT LOCATION degFdegC ACTION TAKEN INITIALS INITIALS

ch04_4597qxd 1222005 349 PM Page 57

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 69: The HACCP Food Safety Employee Manual 0471781827

58 HACCP Star Point 4

STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE

The cook is preparing chicken soup that was made the previous day She started to heat the soup at 8 am in thejacketed steam kettle She forgets to check the soup until 930 am when she finds that the soup has reached150ordmF (656degC) What does she need to do to be sure that the soup reaches the correct temperature for reheatedfoods What could have caused the problem

ch04_4597qxd 1222005 349 PM Page 58

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 70: The HACCP Food Safety Employee Manual 0471781827

Work the Plan 59

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch04_4597qxd 1222005 349 PM Page 59

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 71: The HACCP Food Safety Employee Manual 0471781827

ch04_4597qxd 1222005 349 PM Page 60

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 72: The HACCP Food Safety Employee Manual 0471781827

In Star Point 5 we will discuss the checks-and-balances system of your HACCPplan which is verification and record keeping Verification confirms our plan isworking properly Record keeping or documentation is written proof that yourHACCP system works and that you prepare serve and sell safe food

61

Checks and Balances

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

HACCP

HACCP STAR POINT 5

ch05_4597qxd 1222005 351 PM Page 61

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 73: The HACCP Food Safety Employee Manual 0471781827

62 HACCP Star Point 5

PRINCIPLE 6 VERIFY THAT THE SYSTEMWORKSThere are only two principles that remain in the HACCP plan Verification is a

check or a confirmation that the steps of the plan are working This is the basisof HACCP Principle 6 It ensures that your operation is maintaining an effectivefood safety program and it provides a chance to update the plan as neededVerification will be completed by the supervisor director or even an outside firm

Verification includes specific actions

Who will perform them

What needs to be performed

Where will this be performed

When will they be performed

Why Verification confirms that the HACCP plan is working

How will they be performed

How will they be documented

Verification is necessary when

New equipment is added to the kitchen

New items have been added to the menu

A foodborne illness is associated with a food

A foodborne illness has been reported

Personnel changes

Changes are made to the Food CodeRegulations

Here are some forms of verification

Observe employees performing tasks especially monitoring CCPs

Check critical control point records

Review monitoring records

Check equipment temperatures

Review hazard analysis and CCPs

Understand why foods havenrsquot reached their critical limits

Determine causes for equipment failure and procedure failure

As a foodservice employee realize that a new menu or a concept change will requireverification and changes to your HACCP plan Verification is important because itreviews every Star Point and confirms that your HACCP plan is working

Star Point Actions You will learn to

Confirm that the system works (HACCP Principle 6)

Maintain records and documentation (HACCP Principle 7)

HACCPPlan

PRINCIPLE 6

ch05_4597qxd 1222005 351 PM Page 62

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 74: The HACCP Food Safety Employee Manual 0471781827

Checks and Balances 63

PRINCIPLE 7 RECORD KEEPING ANDDOCUMENTATION

To achieve the final HACCP principle you must document the corrective actionsyou have taken and record the measurements used while monitoring the foodproduct to show the food product is being monitored The final HACCP principleinvolves all the paperwork documents logs etc that you have maintained as youhave protected the flow of food It is critical when documenting to get enoughinformation to ensure your HACCP plan is effective All records must be accurateand legible Never scribble or use correction tape or liquid because it may look likea cover up For errors always draw a line through the mistake and initial Do notfalsify recordsmdashno dry labbing

In order to be effective your record-keeping plans should include the following

HACCP Plan

Standardized Recipes

SOPs

Monitoring Procedures

Shellstock Tags

Grinding Log (Lot rsquos)

Equipment Maintenance Log

List of Approved Chemicals

Forms

Invoices

Schedules

Company Organization Chart

Serving Line Temperature Log

Cold Holding Equipment

Hot Holding Equipment

Cold Serving Equipment

Hot Serving Equipment

Dry Storage Temperature Log

Calibrated Thermometers

Master Cleaning Checklist

Receiving Log

Freezer Log

Discard log (waste chartshrink log)

Pest Control Documentation

Employee Health Records

A log of times and temperatures as well as graphs

Checklists

Corrective actions taken to correct the problem

Records of employee training

Flow charts

Specifications of the food products

PRINCIPLE 7

ch05_4597qxd 1222005 351 PM Page 63

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 75: The HACCP Food Safety Employee Manual 0471781827

Following are samples of the types of forms used for record keeping

Sample Record Keeping Logs

64 HACCP Star Point 5

THERMOMETER CALIBRATION LOG

DATE EMPLOYEE AM TIME MID TIME PM TIME DATE EMPLOYEE AM TIME MID TIME PM TIME

REHEATING LOG

FOOD INTERNAL CORRECTIVE EMPLOYEE MANAGERDATE TIME PRODUCT TEMPERATURE ACTION TAKEN INITIALS INITIALS

DISCARD LOG

bull HOLDFOOD bull DISCARDPRODUCT bull RETURN EXPLAIN ACTION TAKEN EMPLOYEE MANAGER

DATE CODE DESCRIPTION bull CREDIT REASON INITIALS INITIALS

Record keeping provides us with a history that we are following prerequisite pro-grams and the 7 HACCP Priniciples By documenting these steps we are provingthat we are consistently preparing serving and selling safe food

ch05_4597qxd 1222005 351 PM Page 64

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 76: The HACCP Food Safety Employee Manual 0471781827

SAMPLE SOP FOR RECEIVING

Checks and Balances 65

Receiving Deliveries (Sample SOP)

Purpose To ensure that all food is received fresh and safe when it enters the foodservice opera-tion and to transfer food to proper storage as quickly as possible

Scope This procedure applies to foodservice employees who handle prepare or serve food

Key Words Cross-contamination temperatures receiving holding frozen goods delivery

Instructions

1 Train foodservice employees who accept deliveries on proper receiving procedures

2 Schedule deliveries to arrive at designated times during operational hours

3 Post the delivery schedule including the names of vendors days and times of deliveriesand driversrsquo names

4 Establish a rejection policy to ensure accurate timely consistent and effective refusal andreturn of rejected goods

5 Organize freezer and refrigeration space loading docks and store rooms before deliveries

6 Gather product specification lists and purchase orders temperature logs calibrated ther-mometers pens flashlights and clean loading carts before deliveries

7 Keep receiving area clean and well lighted

8 Do not touch ready-to-eat foods with bare hands

9 Determine whether foods will be marked with the date of arrival or the ldquouse-byrdquo date andmark accordingly upon receipt

10 Compare delivery invoice against products ordered and products delivered

11 Transfer foods to their appropriate locations as quickly as possible

Monitoring

1 Inspect the delivery truck when it arrives to ensure that it is clean free of putrid odors andorganized to prevent cross-contamination Be sure refrigerated foods are delivered on arefrigerated truck

2 Check the interior temperature of refrigerated trucks

3 Confirm vendor name day and time of delivery as well as driverrsquos identification beforeaccepting delivery If the driverrsquos name is different than what is indicated on the deliveryschedule contact the vendor immediately

4 Check frozen foods to ensure that they are all frozen solid and show no signs of thawing andrefreezing such as the presence of large ice crystals or liquids on the bottom of cartons

5 Check the temperature of refrigerated foods

a For fresh meat fish dairy and poultry products insert a clean and sanitized thermome-ter into the center of the product to ensure a temperature of 41ordmF or below

b For packaged products insert a food thermometer between two packages being carefulnot to puncture the wrapper If the temperature exceeds 41ordmF it may be necessary totake the internal temperature before accepting the product

c For eggs the interior temperature of the truck should be 45ordmF or below

ch05_4597qxd 1222005 351 PM Page 65

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 77: The HACCP Food Safety Employee Manual 0471781827

66 HACCP Star Point 5

6 Check dates of milk eggs and other perishable goods to ensure safety and quality

7 Check the integrity of food packaging

8 Check the cleanliness of crates and other shipping containers before accepting productsReject foods that are shipped in dirty crates

Corrective Action

1 Reject the following

a Frozen foods with signs of previous thawing

b Cans that have signs of deteriorationmdashswollen sides or ends flawed seals or seamsdents or rust

c Punctured packages

d Expired foods

e Foods that are out of the safe temperature zone or deemed unacceptable by the estab-lished rejection policy

Verification and Record Keeping

Record temperature and corrective action on the delivery invoice or on the receiving log The food-service manager will verify that foodservice employees are receiving products using the properprocedure by visually monitoring receiving practices during the shift and reviewing the receiving logat the close of each day Receiving logs are kept on file for a minimum of one year

Date Implemented ____________________________ By

Date Reviewed ____________________________ By

Date Revised ____________________________ By

STAR KNOWLEDGE EXERCISE

Name three situations when verification should be done to evaluate the HACCP plan Why

1

2

3

ch05_4597qxd 1222005 351 PM Page 66

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 78: The HACCP Food Safety Employee Manual 0471781827

Checks and Balances 67

HACCP

Plan

HACCP PRINCIPLES MATCH GAME

Here is HACCP at a glance Match the principle with the picture

A Establish Critical Limits

B Identify Corrective Actions

C Verify That the System Works

D Determine Critical Control Points

E Conduct a Hazard Analysis

F Establish Procedures for Record Keep-ing and Documentation

G Establish Monitoring Procedures

HACCP Principles Match Game

How many points did you earn _______

If you scored 7 pointsmdashCongratulations You are a HACCP Principles Superstar

If you scored 5ndash6 pointsmdashGood job You have a basic understanding of HACCP principles

If you scored 3ndash4 pointsmdashThe time to review is now What a great opportunity to fine-tune your HACCP princi-ples skills

If you scored 0ndash2 pointsmdashEveryone needs to start somewhere We are confident that if you follow these proce-dures you will learn the basics of HACCP principles Your trainer will help you in this process

ch05_4597qxd 1222005 351 PM Page 67

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo
Page 79: The HACCP Food Safety Employee Manual 0471781827

68 HACCP Star Point 5

In Star Point 5 we discussed the checks and balances system of your HACCPplanmdashverification and record keeping Verification confirms your plan is workingproperly Record keeping is proof that your HACCP plan is working properly

ARE YOU A HACCP ldquoSUPERSTARrdquoThe goal of this manual was to help you the student better understand the

five points in the HACCP Star and to demonstrate how they save lives Each pointof the HACCP star has helped us to create and use an effective HACCP planNow that you have a better understanding of a HACCP plan it is up to you to be avalued HACCP team member by applying the prerequisite programs and HACCPprinciples learned in this book

It is time to take your HACCP exam to test your understanding of this programUpon earning 75 percent or above you will receive your HACCP Superstar Cer-tificate The HACCP certification is valid for four years and is recognized as basicHACCP comprehension for employees Please complete the evaluation on yourtrainer and prepare to take your HACCP exam

Point 5 HACCP Principles 6 and 7 bull Verify bull Record Keeping

Point 4 HACCP Principles 3 4 and 5 bull Critical Limits bull Monitoring bull Corrective Actions

Point 3 HACCP Principles 1 and 2 bull Hazard Analysis bull Determine CCP

Point 1 Prerequisite Programs bull Master

Point 2 Food Defense bull Apply

Complete

Complete

CompleteComplete

Complete

HACCP

ch05_4597qxd 1222005 351 PM Page 68

  • The HACCP Food Safety Employee Manual
    • Contents
    • ACKNOWLEDGMENTS
    • Preface HACCP Star Points to Food Safety
    • HACCP STAR POINT 1 Prerequisite Programs
      • HACCP PRETEST
      • UNDERSTANDING AND USING PREREQUISITE PROGRAMS
      • UNDERSTANDING FOOD SAFETY USING STANDARD OPERATING PROCEDURES
      • STAR KNOWLEDGE SOP EXERCISE
      • COMMON FOODBORNE ILLNESSES
      • MAJOR FOOD ALLERGENS
      • STAR KNOWLEDGE
      • INTERNATIONAL FOOD SAFETY ICONS
      • FOOD SAFETY MATCH GAME
      • EMPLOYEE RESPONSIBILITIES RELATED TO FOOD SAFETY
      • TEMPERATURE DANGER ZONE (TDZ)
      • SERVING FOOD AND OPERATING SELF-SERVICE BARS
      • FOOD SAFETY SOP STAR CONCLUSION
      • ARE YOU A FOOD SAFETY ldquoSUPERSTARrdquo
        • HACCP STAR POINT 2 Defense
          • INTRODUCTION TO FOOD DEFENSE
          • UNDERSTANDING FOOD DEFENSE
          • EMPLOYEE RESPONSIBILITIES IN FOOD DEFENSE
          • REALITY CHECK
          • ARE YOU A FOOD DEFENSE ldquoSUPERSTARrdquo
            • HACCP STAR POINT 3 Create a HACCP Plan
              • HACCP INTRODUCTION
              • THE HACCP PHILOSOPHY
              • PRINCIPLE 1 CONDUCT A HAZARD ANALYSIS
              • STAR KNOWLEDGE EXERCISE
              • PRINCIPLE 2 DETERMINE CRITICAL CONTROL POINTS
              • FOOD FLOW CHART EXAMPLE
              • STAR KNOWLEDGE EXERCISE
              • STAR KNOWLEDGE EXERCISE
                • HACCP STAR POINT 4 Work the Plan
                  • PRINCIPLE 3 ESTABLISH CRITICAL LIMITS
                  • STAR KNOWLEDGE CRITICAL LIMIT EXERCISE
                  • PRINCIPLE 4 ESTABLISH MONITORING PROCEDURES
                  • STAR KNOWLEDGE MONITORING EXERCISE
                  • PRINCIPLE 5 IDENTIFY CORRECTIVE ACTIONS
                  • STAR KNOWLEDGE CORRECTIVE ACTION EXERCISE
                    • HACCP STAR POINT 5 Checks and Balances
                      • PRINCIPLE 6 VERIFY THAT THE SYSTEM WORKS
                      • PRINCIPLE 7 RECORD KEEPING AND DOCUMENTATION
                      • STAR KNOWLEDGE EXERCISE
                      • HACCP PRINCIPLES MATCH GAME
                      • ARE YOU A HACCP ldquoSUPERSTARrdquo