the haccp food safety employee manual 0471781827
TRANSCRIPT
The HACCP FoodSafety Employee
Manual
Tara Paster
John Wiley amp Sons Inc
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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
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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
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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
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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
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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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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
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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
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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)
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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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-
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
-