the haccp recipe for process innovation ... haccp recipe for process innovation haccp recipe...

THE HACCP RECIPE FOR PROCESS INNOVATION

HACCP Recipe Workshop and Certificate

Cooking and Chilling Technologies for the 21st Century October 25-26, 2004

Long Beach, California

Hospitality Institute of Technology and Management 670 Transfer Road, Suite 21A

St. Paul, Minnesota 55114 TEL 651 646 7077 FAX 651 646 5984

http://www.hi-tm.com [email protected]

presentations:CCRS-20004-HACCP recipe orig 9/28/04 rev 10/21/04 print 10/22/04 1

mailto:[email protected]

HOSPITALITY INSTITUTE OF TECHNOLOGY AND MANAGEMENT

Purpose To facilitate new retail process innovation using food science and equipment technology so that new products such as chilled and acidified shelf-stable food can be produced while reducing operating costs.

•

• To help companies implement AMC-HACCP operating programs that will allow them to do product development and innovation, and to strive for zero defects in safe and quality food production.

Clients Major national / international retail food operations who cannot afford to make mistakes.


THE HACCP RECIPE FOR PROCESS INNOVATION Learning Outcomes

1. Be able to identify and specify a food process system. Inputs Processes Outputs

2. Identify the biological, chemical, and physical hazards and which are significant. 3. Identify prerequisite processes. 4. Group food processes by hazard controls and shelf stability. 5. Understand the process times and temperatures for process control. 6. Understand integrated lethality vs. point lethality. 7. Describe the cook-package and package-cook chilled food processes. 8. Specify pH and aw controls for pasteurized shelf-stable food. 9. Describe what are chilled food functional ingredients and GRAS. 10. Describe how to do a food process HACCP plan. 11. Be able to write a HACCP recipe. 12. Describe what are Standards of Identity. 13. Describe how to do a validation of a HACCP plan. 14. Describe the elements of a food safety policies, procedures, and standards manual

and Active Managerial Control.


CHILLED FOOD SYSTEM

lunds:audit-jan04 093




pictures:feedthru-bag


pictures: tipperclippers


MENU ITEMS CATEGORIZED BY PRODUCTION CATEGORIES / CENTERS USDA and FDA Items

1. Thick Foods USDA Ham, Glazed Turkey, Glazed Chicken Breast 2. Thin Foods COLD: USDA Roast Beef, Sliced Turkey Breast, Smoked 3. Sauces, Soups HOT SAUCES: USDA Chicken Bolognese Sauce HOT SAUCES: FDA Barbecue Sauce Spaghetti Sauce HOT SOUPS: USDA Chicken Noodle Chili with Beans HOT SOUPS: FDA Cream of Asparagus Cream of Broccoli

HOT SOUPS: SEAFOOD FDA New England Clam Chowder COLD SAUCES: FDA Dressings 1000 Island Dressing French Dressing Dips and Sauces Caramel Fruit Dip Dill Dip Other Pumpkin Filling Marinades (FDA) Buttermilk Sun-dried Tomatoes Tandoori Beverages (FDA) Lemonade 4. Fruits, Vegetables, Starches COOKED VEGETABLES: FDA Mashed Potatoes Spaghetti

RAW, VEGETABLES: FDA Cabbage, Green Shred Carrots, Diced Onions, Whole Potatoes, Whole 5. Breads, Pastries: FDA items Garlic Toast PIES French Silk Pie Grasshopper Pie Quiche Crust CAKES Banana Nut Loaf Carrot Chocolate COOKIES Sugar Spritz CROISSANT DOUGH (made and shipped raw or frozen) Butter Croissant Danish

6. Hot Combinations KETTLE: USDA ITEMS Barbecue Chicken Wings Beef Pot Pie Beef Stew Stuffings: USDA FDA ITEMS Hot combination Au Gratin Potatoes Chow Mein (Meatless) Company Hashbrowns Stuffing: FDA Sage Dressing Wild Rice 7. Cold Combinations SALADS: USDA Chicken Salad SALADS: FDA Potato Salad Tuna Salad


EXAMPLES OF SOUS VIDE FOOD

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11

12

4

7

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15

9 10 pics:sousvide:food-pkg


ESTIMATED ANNUAL FOODBORNE ILLNESSES, HOSPITALIZATIONS, AND DEATHS DUE TO SELECTED PATHOGENS, UNITED STATES, 1999

Number

Disease or Agent Illnesses Hospitalization Deaths

Comment

Bacterial Campylobacter spp. 1,963,141 10,539 99 A small percentage of people develop Guillain-Barré

Syndrome. Clostridium perfringens 248,520 41 7 Usually causes mild gastrointestinal distress lasting only a

day. Escherichia coli O157:H7 62,458 1,843 52 Usually a mild gastrointestinal illness, but severe

complications such as bloody diarrhea and kidney failure may develop [e.g., hemorrhagic colitis and hemolytic uremic syndrome (HUS)].

Listeria monocytogenes 2,493 2,298 499 Women infected with Listeria during pregnancy may transmit the infection to the fetus, possibly leading to stillbirths or babies born with mental retardation.

Salmonella, non-typhoidal 1,341,873 15,608 553 Relatively mild and common Staphylococcus foodborne illness

185,060 1,753 2 Characterized by severe nausea, vomiting, cramps, and diarrhea.

Vibrio cholerae, toxigenic 49 17 0 Causes epidemic cholera. Viral Norwalk-like viruses 9,200,000 20,000 124 Characterized by nausea, vomiting, diarrhea, and

abdominal pain. Easily transmitted. Parasitic Toxoplasma gondii 112,500 2,500 375 Infection may be transmitted to fetuses, possibly leading to

stillbirths or babies born with birth defects ranging from hearing or visual impairments to mental retardation.

Reference: Busby, J.C., Frenzen, P.D., and Rasco, B. 2001. Product liability and microbial foodborne illness. USDA ERS. Agricultural Economic Report

#799. Washington, DC. p. 5. (Source: data from Mead et al., 1999.)


FOOD MICROBIOLOGICAL CONTAMINATION MICROORGANISM SOURCE PERCENT CONTAMINATED

Salmonella spp. Raw poultry Raw pork Raw shellfish

40 - 100 3 - 20

16 Staphylococcus aureus Raw chicken

Raw pork Raw beef

73 13 - 33

16 Clostridium perfringens Raw pork and chicken 39 - 45 Campylobacter jejuni Raw chicken and turkey 45 - 64 Escherichia coli O157:H7 Raw beef/pork/poultry 1.5 - 3.7 Bacillus cereus Raw ground beef

Raw rice 43 - 63

100 Listeria monocytogenes Fresh potatoes

Fresh radishes 26 30

Yersinia enterocolitica Raw pork Raw milk Raw vegetables

49 48 46

Vibrio spp. Raw seafood 33 - 46 Giardia lamblia, Norovirus Water 30

HUMAN MICROBIOLOGICAL CONTAMINATION MICROORGANISM SOURCE PERCENT CONTAMINATED

Shigella spp., hepatitis A, Norovirus, E. coli, Salmonella spp., Giardia lamblia

Feces

Norovirus Vomit Staphylococcus aureus Skin, nose, boils and skin

infections Streptococcus Group A Throat and skin

1 in 50 (2%) of the employees who come to work each day is highly infective.


THE RAW FOOD CONTAMINATION PROBLEM

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FOOD CODE INACCURACIES

Code Requirement Actual / Science Plan review is essential for safe food. Hazard control of cleaning and food process, not facility

plan review, controls hazard. NSF assures equipment safe holding / processing / cooling. NSF equipment not validated in operation to perform

reliably to code temperatures and cleanability. Potentially hazardous food. Contamination with non-multiplying pathogens, chemicals, and physical objects is OK.

Risk analysis; it is a risk only if there is evidence of significant illness or injury.

pH control 4.6; aw control 0.85. Inaccurate. Vegetative cell control pH 4.1, aw <0.86. Spore control pH <4.6 Clostridium botulinum, <4.3 Bacillus cereus, aw 0.92.

Hand washing, lather 20 seconds. Not validated. Double wash with nail brush, friction, and flowing water dilution gives 1,000,000-to-1 reduction.

To clean a food contact surface, wipe with a rag from a sanitizer bucket. Not validated.

Dilute with detergent rag 10-3, dilute with rinse rag 10-2. Dish machine, wash tank make ware safe.

Raw and cooked food cold holding, 41ºF. Not safe. Time and temperature 19 days, 35ºF; 7 days, 41ºF; 4 days, 45ºF, etc.

Rapid and progressive growth, 41 to 135ºF. Inaccurate. Rapid growth 80 to 120ºF. Bimetallic coil thermometer. Inaccurate. Tip-sensitive thermistor or thermocouple. Thermometer

calibrated by measuring deviation from standard. Roast beef cooked to 130ºF, 112 minutes, displayed at 130ºF, but other food >145ºF. Inaccurate.

Actually cooked in food operations to 115ºF. Raw prime safe because of low raw meat Salmonella counts.

Hot holding beef 130ºF; all other hot foods 135ºF. Inaccurate.

125ºF is safe for all hot foods. Control surface cooling.

Cooling from 135 to 70°F within 2 hours followed by cooling to 41°For below within a total cooling time of 6 hours. Wrong.

120 to 55ºF in 6 hours and to 40ºF in 14.2 hours is safe (2-inch pan or 1-gallon container.

Cooked food holding 41ºF, 7 days; from 42 to 139ºF, 4 hours. Very inaccurate.

It is progressive. 115ºF, 4.6 hours; 90ºF, 8 hours; 60ºF, 1.2 days; 41ºF, 7 days; 35ºF, 19 days.

Reheating 165ºF, 15 seconds, in less than 2 hours. Unsafe. Do not use; will not control toxins and poisons. To be anaerobic, food must be in an airtight jar, can, or plastic bag. Inaccurate

Any food more than 1/4 inch below the surface is anaerobic.


USE HACCP

FROM: FDA. 2001. Food Code. U.S. Public Health Service, U.S. Dept. of Health and Human Services. Washington, D.C. http://www.cfsan.fda.gov/~dms/fc01-toc.html.

4. ADVANTAGE OF UNIFORM STANDARDS Federal performance standards:

Use of HACCP and performance standards as the measure of regulatory compliance means establishments are free to use innovative approaches in producing safe products such as specified cooling times and temperatures from USDA, that achieve the same end. (Adapted from Preface, page iv)

Retail operators may be given the same opportunity as federally-regulated establishments to use innovative techniques in the production of safe foods. However, to show compliance with the federal performance standard, the retail processor must, like a federally inspected establishment, show that processing controls are in place to ensure that the standard is being met. Thus, a request for a variance based on a federal performance standard must be supported by a validated HACCP plan with record keeping and documented verification being made available to the regulatory authority. (Preface, page v)


BECOMING USDA AND FDA INSPECTED

Simply manufacture for commercial sale

Any process that you can prove is safe •

•

• •

• • •

FDA: non-meat and poultry

Inspections based on your inspection score: 1 per year to 1 per 5 years; no cost No requirement for HACCP, but asks HACCP questions You must do nutrition labeling

USDA inspection: >3% raw meat and poultry or >4% cooked meat and poultry

Daily inspection, but no cost for 8 hours , 5 days a week Must have a parking place and office for inspector Must have a HACCP team plan and validate processes (you need these anyway for quality control)


ANTECEDENTS FOR HACCP RISK MANAGEMENT (Active Managerial Control)

1.

2.

3.

4.

5.

6.

7.

8.

Management commitment: time and money; budget; enforcement

Management risk assessment capability: HACCP team

Hazard inventory of the system: facilities / equipment; personnel; supplies; food products / menu

Selection and validation of controls

Written program / policies, procedures, and standards checklist

Employee procedures control training

Process operation and performance data collection: items on the policies, procedures, and standards checklist

HACCP team meeting: corrective action


THE UNIT AS A FOOD PROCESS SYSTEM


PERFORMANCE-BASED AMC-HACCP SELF-INSPECTION Food System Performance Requirements

MANAGEMENT, HACCP TEAM 1. Self-assessment 2. Cooks trained and know hazards 3. HACCP team audit; improvement PREREQUISITE PROCESSES / SSOP / GMP 1. Personal Hygiene

a. Double fingertip wash after toilet b. Single fingertip wash with raw

food 2. Environment / Facilities

a. Safe water b. Toxic items, chemicals controlled

3. Equipment a. Adequate capacity b. Food contact surface rinse, wash

4. Food Source, Receiving, and Storage a. Sources provide HACCP

intervention b. Food received ≤40ºF or 10ºF

FOOD HACCP PROCESSES 1. Physical hazards reduced to <1/16 inch 2. Allergen control; know ingredients 3. Additives used according to CFRs 4. Double washing fruits and vegetables 5. Cooking pasteurization, 150ºF, >1 minute 6. Hot hold, transport, serve / catering >125ºF 7. Spore pathogen control: pH <4.6 or 4.3, aw

<0.92 Vegetative pathogen control: pH <4.1, aw <0.86

8. Cooling 120 to 55ºF, 6 hours; to 40ºF, 14.2 hours

9. Cold hold, transport, serve / catering, <3 log increase in pathogens (Bacillus cereus)

10. Salads mixed with ingredients, <50ºF 11. Fresh not added to old 12. Take out: Customers advised to eat in <4

hours or refrigerate immediately


POTENTIAL HAZARDS IN THE FOOD SYSTEM

CHEMICAL PHYSICAL BIOLOGICALPoisonous Substances

Toxic plant material Intentional additives Chemicals created by the process Agricultural chemicals Antibiotic and other drug residues Unintentional additives Sabotage Equipment leaching Packaging leaching Industrial pollutants Heavy metals Radioactive isotopes

Adverse Food Reactions (food sensitivity)

Food allergens Food intolerances

Metabolic disorder Pharmacological reactions

Idiosyncratic reactions Anaphylactoid reactions

Nutrition

Hard Foreign Objects Glass Wood Stones Metal Packaging materials Bones Building materials Personal effects

Functional Hazards

Particle size deviation Packaging defects Sabotage

Choking / Food Asphyxiation Hazards

Pieces of food Thermal Hazards

Food so hot that it burns tissue

Microorganisms and their Toxins Bacteria: vegetative cells and spores Molds [mycotoxins (e.g., aflatoxin)] Yeasts (Candida albicans) Viruses and rickettsia Parasites

Fish and Shellfish as Sources of Toxic Compounds

Pests (birds, insects and rodents) as carriers of pathogens Filth from insects, rodents, and any

other unwanted animal parts or excreta


FOOD DEFECT ACTION LEVELS Levels of natural or unavoidable defects in foods

that present no health hazards for humans

Product Defect: Action Level Broccoli, frozen Insects and mites: Average of 60 or more aphids, thrips, and/or mites

per 100 grams Fish, fresh or frozen (applies only to fish or fillets weighing 3 pounds or less)

Decomposition: Decomposition in 5% or more of the fish or fillets in the sample (but not less than 5) show Class 3 decomposition over at least 25% of their areas in 2 or more subsamples, etc.

Macaroni and noodle products

Insect filth: Average of insect fragments equals or exceeds 225 per 225 grams in 6 or more subsamples Rodent filth: Average of rodent hairs equals or exceeds 4.5 per 225 grams in 6 or more sub-samples

Pepper, Ground Insect filth: Average of 475 or more insect fragments per 50 grams Rodent filth: Average of 2 or more rodent hairs per 50 grams.

Tomato catsup Mold: Average mold count in 6 subsamples is 55% Tuna, canned: Albacore, Skipjack, and Yellowfin

Decomposition: Odors of decomposition or Honey-combed tissue or Histamine ≥5 mg/100 grams in 2 or more cans

Wheat flour Insect filth: Average of 75 or more insect fragments per 50 grams Rodent filth: Average of 1 or more rodent hairs per 50 grams

* FDA. 1998. The Food Defect Action Levels. Department of Health and Human Services. Public Health Services, Food and Drug

Administration, Center for Food Safety and Applied Nutrition, Washington, D.C. 20204. http://vm.cfsan.fda.gov/~dms/dalbook.html


FOOD PATHOGEN CONTROL DATA SUMMARY

Microorganisms and source

Temperature range for growth, atmosphere

pH range and minimal water activity (aw) for growth

Infective Microorganisms (Inactivated by pasteurization) 1. Yersinia enterocolitica

Feces / food 29.3-111°F Aerobic but may be facultative

4.6-9.0 pH

2. Listeria monocytogenes Feces / food

29.3-112°F Facultative, grows in 5% salt

4.5-9.5 pH 0.93 aw

3 Vibrio parahaemolyticus Seafood / water

41-109.4°F

Facultative anaerobe 4.5-11.0 pH

0.937 aw 4. Salmonella spp.

Feces / food 41.5-114°F Facultative

4.1-9.0 pH 0.95 aw

5. Escherichia coli O157:H7 Feces / food

44.6-114ºF Facultative

4.0-9.0 pH 0.95 aw

6. Campylobacter jejuni Feces / food

90-113°F Obligate microaerophile

4.9-8.0 pH

7. Staphylococcus aureus 43.8-122°F Facultative, grows in 10% salt and produces toxin, 50-114.8°F

4.5-9.3 pH 0.83 aw 5.15-9.0 pH 0.86 aw

Toxin Producers and/or Spore-formers (Not inactivated by pasteurization) 8. Clostridium botulinum, (Type E and

other non-proteolytic strains) 38-113°F Anaerobic, grows in up to 5% salt

5.0-9.0 pH 0.97 aw

9. Bacillus cereus 39.2-122°F Aerobic, but can be facultative

4.3-9.0 pH 0.912 aw

10. Clostridium botulinum, (Type A and Proteolytic B strains)

50-118°F Anaerobic, grows in up to 5% salt

4.6-9.0 pH 0.94 aw

11. Clostridium perfringens 59-126.1°F Facultative anaerobe

5.0-9.0 pH 0.95 aw


MEASURING

Thermometers. Calibration pH Meter. Calibration Bag Feed-Through.


STANDARDIZED MONITORING What to Measure How to Measure

Food temperature in cold holding (delivery, receiving, refrigerator)

Measure 1/8 to 1/4 inch below the top surface.

Cooked, pasteurized food Measure temperature of center of thickest food item. Hot hold display Measure 1/8 to 1/4 inch below the top surface. Cooling Push through the thickest part of the food to find the

warmest temperature. Cold hold display Measure 1/8 to 1/4 inch below the top surface Refrigerator air temperature Measure cup of salt, 8 oz., on the center shelf for >1

hour to stabilize. Oven temperature Measure cup of salt, 8 oz., on the center shelf for >1

hour to stabilize. Oven humidity Use a thermocouple in a cotton wick in water with air

circulation. Fryer Using a tip-sensitive thermometer, measure oil

temperature for 3 cycles and take the average. Food pH At 20ºC, measure pH with a strip or meter. Food can

be diluted by 30% with distilled water, if needed. Food aw Use a Decagon aw meter or equivalent. Surface safety Using Petrifilm™, do a contact plate or swab and look

for <100 colonies per 8 square inches.


PROCESSES CAN BE GROUPED BY FOOD SAFETY HAZARDS

I.

II.

III.

Not heat treated, not shelf stable. sashimi; lettuce and coleslaw salads; fruit salads; sprouts; yogurt; sauerkraut; kimchee; salsa Not heat treated product with secondary inhibitors, not shelf stable. corned beef Heat treated, not fully cooked, not shelf stable. meat, fish, poultry; fruits and vegetables

IV. Heat treated, not fully cooked, with inhibitors to make shelf stable. pepperoni; salami; ham; salted, dried fish; cheese; sugar; honey; salad dressing; beer; wine

V.

VI.

VII.

Fully cooked, not shelf stable. hot or cooled, refrigerated ready-to-eat food; meat, fish, poultry; fruits and vegetables, dairy Fully cooked, with inhibitors to make shelf stable. marinara sauce; béarnaise sauce; pie fillings; sushi rice; smoked fish; salted fish; canned, low-pH fruits and vegetables; bread, dry cereals, pasta Commercially sterile, shelf stable. canned meat, fish, poultry; canned dairy products


FDA FOOD CODE HOLDING / STORAGE RECOMMENDATIONS WITH HITM MODIFICATION

Temp. (°F)

1 Generation

10 Generations

30 293.5 123.8 da 35 45.7 19.3 da40 18.2 7.5 da41 15.6 6.5 da45 9.5 4.0 da50 5.9 2.4 da55 4.0 1.7 da60 2.9 1.2 da70 1.69 16.9 h80 1.11 11.1 h90 0.79 7.9 h

100 0.59 5.9 h110 0.47 4.7 h115 0.46 4.6 h120 0.56 5.6 h

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

1.6

0 20 40 60 80 100 120 140

Temperature (oF)

[1/g

ener

atio

n (h

)]1/2

Bacterial Pathogensy = 0.015x-0.4364

HITM - adapted FDA Food Code y = 0.032*(temp oC -(-2.924))*(1-Exp (0.444 *(temp oC - 52.553)))

Spoilage bacteriay= 0.016x-0.2969

25

100

11.1

6.3

4.0

2.8

1.6

1.2

1.0

Time (hours)

0.69

0.83

0.590.5

0.4

2.0

spoilbac/Chart9 125 3.1 31.0 h

1382


CALCULATED GENERATION TIMES FOR BACILLUS CEREUS

Tim

e (h

ours

) per

gen

erat

ion

Temp. ºF

Hours per generation

70 0.9465 1.2160 1.6655 2.4754 2.7053 2.9852 3.3051 3.6950 4.1449 4.6948 5.3647 6.1946 7.2345 8.5744 10.3243 12.6842 15.9741 20.7540 28.07

0.4

1.0

4.0

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DESTRUCTION OF SALMONELLA IN FOOD

DESTRUCTION OF SALMONELLA SPP. IN FOOD

6.7 sec. 5.2 sec. 160 (71.1)

21 sec. 16 sec. 155 (68.3)

67.sec. 52 sec. 150 (65.6)

3.5 min. 2.7 min. 145 (62.8)

11.2 min.8.7 min. 140 (60.0)

35 min. 27 min. 135 (57.2)

112 min. 86 min. 130 (54.4)

6.5D Roast beef

(3,160,000:1)

5D Hamburger (100,000:1)

Temp. ºF (ºC)

DEATH CONTROLS Time and temperature Nutrients and acids Water activity

1326


FDA VS. HACCP PROCESS CONTROL STANDARDS Process Step FDA Performance Standard HACCP Performance Standard

Receiving, storage, pre-preparation

41ºF. Not a CCP. Receive at any temperature. 5D cooking reduces vegetative pathogens on meat, poultry, and fish to a tolerable level. Growth of pathogens on raw vegetables not an identified significant hazards. If food is to be served without washing or pasteurization, the supplier assures safety.

Preparation Fruit and vegetable washing

None. 2D wash E. coli reduction; 5D surface blanch E. coli reduction.

Pasteurization Meat, fish, fruits, vegetables, bakery

130ºF, 112 min.: beef 135ºF, 27 min.; 140ºF, 9 min.; 145ºF, 3 min.; 150ºF, 1 min.; 155ºF, 15 sec.

5D Salmonella (E. coli) reduction.

Poultry 165ºF, 15 sec. Hot hold, transport, serve, package

130ºF beef; 135ºF everything else. <1-log increase Clostridium perfringens, which begins to multiply ~125ºF, and at 105ºF, multiply every 15 min.

Cool 135 to 70ºF, 2 hr.; 70 to 41ºF, 4 hr. 120 to 55ºF, 6 hr. and continue to 40ºF (14.2 hr.) or <1-log increase of C. perfringens or Bacillus cereus (USDA).

Packaging ready-to-eat food

None. No detectable Listeria monocytogenes (<1 / 25 g) in ~3 samples every 3 months.

Cold hold 41ºF, 7 days. No standard. Until spoiled <50ºF Clostridium botulinum control, <40ºF B. cereus control.

Shelf stable processed food

Vegetative cells <4.6 pH C. botulinum, <0.86 aw Salmonella.

<4.1 pH Salmonella, <0.86 aw Staphylococcus aureus.

Spores <4.6 pH C.botulinum, <4.3 pH B. cereus, <0.92 aw B. cereus. Reheat 41 to 165ºF, 15 sec., 2 hr. No standard. Consumer abuse

None. <3-log increase B. cereus.


HEATING AND COOLING CURVE For a Vacuum-Packed Chicken Breast

chixclr.xls&jpg


FOOD PASTEURIZATION LETHALITY PLOT

FdPasteurizationLethal.xls/ch1/fd-past-leth.jpg

Food Pasteurization Lethality Calculation

Temp. T (°F)

Time t (sec.)

Lethality (sec.)

141.0 60 0.755143.4 60 1.313146.0 60 2.389148.6 60 4.347151.2 72 9.491153.6 72 16.494156.2 84 35.017158.4 120 83.020159.2 96 79.849158.4 24 16.604154.0 24 6.029148.0 24 1.514142.2 24 0.398Total lethality = 257.220 sec


WATER TANK COOKING AND COOLING PROCESS Pork Roast


RETAIL HACCP PLANS FOR USDA PROCESSES

Not Heat Treated, Not Shelf Stable (Refrigerated)

sashimi; lettuce and coleslaw salads; fruit salads; sprouts; yogurt; sauerkraut; kimchee; salsa

Fully Cooked, Not Shelf Stable (Refrigerated)

hot or cooled, refrigerated ready-to-eat food; meat, fish, poultry;

fruits and vegetables, dairy

Heat Treated, Not Fully or Fully Cooked, with Inhibitors to

Make Shelf Stable pepperoni; ham; salted, dried

fish; cheese sauce, BBQ sauce; salad dressing; beer; wine

CCP. Raw food: Grow with tolerable levels of pathogens

Raw food: receive, store, pre-preparation

Raw food: receive, store, pre-preparation CCP. Add inhibitors to make shelf stable

CCP. Preparation CCP. Preparation Ferment, dry, wax, wash

Cook

Package-cook

CCP. Preparation heat treat

CCP. Transport, Hold, Serve

CCP. Transport, Hold, Serve

Transport, Hold, Serve

CCP. Cool

CCP. Cool pan

CCP. Cool package

Cool

CCP. Store – Sell - Consumer Take-Out

CCP. Store – Sell - Consumer Take-Out

Store – Sell - Consumer Take-Out


USDA-SPECIFIED CHILLED FOOD PROCESSES*

Package-Then-Cook 1. Assemble -- Sear -- Package -- Cook -- Chill • Sous vide

Rolls and roasts, chops, pieces of meat Canned crab and ham

PRE-PREP VACUUM PACKAGE PASTEURIZE CHILL

Cook-Then-Package

2. Assemble -- Cook -- Package above 160°F (71.1°C) – Chill • Stews, casseroles,

sauces, soups Meat, pasta, vegetables, sauce combination, mashed potatoes

PRE-PREP PASTEURIZE AND PACKAGE HOT CHILL

3. Cook -- Chill -- Assemble – Package • Roast or fried chicken

Other roasts Uncured sausages

PRE-PREP PASTEURIZE CHILL PACKAGE

• Uncured luncheon meat

Diced meat PRE-PREP PASTEURIZE CHILL SLICE/DICE PACKAGE

• Meat and pasta dinner

Meat and sauce Sandwiches and pizza

PRE-PREP PASTEURIZE CHILL ASSEMBLE PACKAGE

• Meat pies, quiches

patties, pates PRE-PREP PASTEURIZE FILL IN CHILL PACKAGE

DOUGH 4. Assemble with Cooked and Raw Ingredients – Package [chill, pasteurize (heat), or serve cold] • Chef's salad

Chicken salad Sandwiches, pizza with raw ingredients

PRE-PREP/ CHILL ASSEMBLE OPTIONAL PACKAGE DISINFECT COOK/CHILL

• Uncured meats PRE-PREP PASTEURIZE ADD RAW CHILL TO PACKAGE

INGREDIENTS GEL * Note: Food that is frozen after processing can have 20,000 to 50,000 microorganisms per gram.


HACCP FLOWS-CHILLED FOOD PROCESSES


CHILLED FOOD COOKING HACCP

Process – Equipment Process Steps Kettle

1. Cut / portion. Make roux. 2. Meat / poultry sear. 3. Add liquid (water). 4. Cook / pasteurize 5D; thicken; flavor. 5. Add cooked 5D / additional ingredients

(potatoes, rice, pasta, vegetable). 6. Package-cool or cool-package

40ºF, <14.2 hours. Store 40ºF. Tank / Convection Steamer

35ºF

Roasts / chops / stew, beef 1. Cut, portion; pump with liquid. 2. Package. 3. CCP. Cook / pasteurize 5D. 4. Cool 40ºF, <14.2 hours. Store 40ºF.

Oven / Broiler / Fryer

Package

35ºF

Chicken / chops / meatballs / fish 1. Cut, portion. 2. Marinade, batter. 3. CCP. Cook / pasteurize 5D. 4. Package-cool or cool-package

40ºF, <14.2 hours. Store 40ºF.


SHELF-STABLE RECIPES WITH pH AND Aw CONTROL

1. Ingredients with enough acid (acetic, citric, lactic) to get equilibrium pH of ≤4.3, (Bacillus cereus spore control) OR Ingredients with enough salt or sugar to get a water activity of <0.92 (Bacillus cereus spore control).

2. Cook / mix. Add mold and yeast inhibitors (e.g., benzoate, sorbate). Add thickeners.

3. If there are solid ingredients (e.g., meatballs, eggs), add them and package. Wait 1 to 3 days. The protein in the added ingredient will tend to combine with some of the acid, and the pH will rise. Verify that the final pH at equilibrium is <4.3 for Bacillus cereus or <4.6 for Clostridium botulinum. Verify aw, if that is being used for control.


ACID CONTROL OF FOOD

Marinade Crue • •

•

•

•

Important for microbiological growth. Oil prevents evaporation.

Cut into small pieces and put in the bottom of a shallow pan in order to keep meat off of the bottom of the pan: 1 medium carrot 4 shallots 2 cloves garlic 1 small sprig thyme Pinch of crushed pepper 2 onions 1 rib celery 2 sprigs parsley 1 bay leaf 12 cloves Add to cover the meat: 4 1/2 cups red wine (pH =3.5) 2 cups vinegar (pH = 2.5) (pH wine and vinegar = 3.35) Add to the surface to prevent evaporation: 1 cup oil

Hollandaise Sauce Room-temperature safe if the final pH is 4.1 or less.

2 egg yolks (pH 6.35) 3 tbsp. lemon juice (pH 2.45) 1/2 cup butter (pH 6.0) (pH of egg yolks, lemon juice, and butter combined = 3.2)

Mayonnaise Discourages growth of Salmonella spp. and other pathogenic bacteria. Must be refrigerated to prevent mold and yeast multiplication.

1 egg yolk (pH 6.35) 1 tsp. sugar 1/4 tsp. salt 1 tsp. dry mustard 2 tbsp. lemon juice or vinegar (pH 2.45) 1 cup oil (pH of oil, egg yolk, and lemon juice or vinegar combined = 3.5)


INGREDIENTS: GRAS AND PERMITTED LIMITS GRAS = Generally Recognized As Safe

In the 1958 food additive amendments to the Food, Drug, and Cosmetic Act (FDCA), certain food ingredients were exempted from the required pre-market evaluation and approval. These GRAS ingredients are generally recognized among qualified scientific experts to be safe under the conditions of their intended us. •

•

•

•

•

•

•

• • • • • • • • • •

Spices and other natural seasonings and flavorings Essential oils, oleoresins (solvent-free), and natural extractives (including distillates) Natural extractives (solvent-free), used in conjunction with spices, seasonings, and flavorings Certain other spices, seasonings, essential oils, oleoresins, and natural extracts Synthetic flavoring substances and adjuvants Substances migrating from cotton and cotton fabrics used in dry food packaging

Substances migrating to food from paper and paperboard products Multiple-purpose GRAS food substances Anti-caking agents Chemical preservatives Emulsifying agents Dietary supplements Sequestrants Stabilizers Nutrients Direct food substances affirmed as GRAS Indirect food substances affirmed as GRAS


POTENT ANTIMICROBIAL ACTIVITY OF SPICES

Antimicrobial Activity Spice

Strong Cinnamon, Clove, Mustard

Medium Allspice, Bay Leaf, Caraway, Coriander, Cumin, Oregano, Rosemary, Sage, Thyme

Weak Black Pepper, Red Pepper, Ginger

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


CHILLED FOOD FUNCTIONAL INGREDIENTS

Flavors Spices, herbs McCormick Flavors (www.mccormickflavor.com) Cheese flavors Kraft Food Ingredient (www.kraft.com) Flavors, color and texture for soups, salad dressings,

snack food coatings and canned food products Sensient Flavors (www.sensient-tech.com)

Antioxidants Butylated hydroxyanisole (BHA) Maximum concentration = 0.02 percent based on weight

of the fat or oil

Eastman Chemical Company (www.eastman.com)

Ethylenediaminetetraacetic Acid (EDTA) Chelating agent. Use in approved foods is in the range of

100 to 300 ppm

Dow Chemical (www.dow.com)

Ascorbic Acid Used in combination with BHA and BHT to regenerate

them following chemical changes they may undergo when they prevent fat rancidity. GRAS when used in accordance with good manufacturing practice.

ADM Food Additives Division; Archer Daniels Midland Company

(www.admworld.com)

Thickeners Starches, gums, methocell National Starch and Chemical Company

(www.nationalstarch.com) Tate & Lyle PLC (www.tateandlyle.com) (formerly

A.E. Staley Manufacturing Company) presentations: CCRS-2004-HACCP recipe orig 9/28/04 rev 10/19/04 print 10/22/04 42

CHILLED FOOD FUNCTIONAL INGREDIENTS (CONT'D)

Microbiological Inhibitors

Additive Example in Food Food Acids (pH control) Acetic Acid – GRAS (when used in accordance with good manufacturing practice). Citric Acid – GRAS (when used in accordance with good manufacturing practice). Lactic Acid – GRAS (when used in accordance with good manufacturing practice). Benzoic Acid (Benzoates) – GRAS (with a limitation of 0.1 percent when used in

accordance with good manufacturing practice). Propionic acid (Propionates) – GRAS (when used at a level not in excess of the

amount reasonable required to accomplish the intended effect). Sorbic acid, Sorbates FDA, 21CFR 181.23, 182.309 – GRAS (when used in accordance with good

manufacturing practice except that it is not used in meats or in foods recognized as sources of vitamin B1, or in fruits and vegetables intended to be sold or served raw or to be presented to consumers as fresh).

USDA, 9CFR 318.7 – Limitation of 0.1 percent individually, or if used in combination with its salts or benzoic acid or its salts, 0.2 percent (expressed as the acids in the weight of the finished product). Not allowed in cooked sausage.

Pickled meat, fish, and vegetable products Soft drinks, fruit drinks Cheese spreads, olives, salad dressing mixes Pickles, acid sauces and salads, semi-preserved fish,

fruits juices, soft drinks, jams, margarines Beverages, canned lemon juice, dried fruits and

vegetables, wine, bread Fresh and processed cheese, dairy products, bakery

products, fruit juice, acid sauces and salads, jams, jellies, soft drinks, margarine, semi-preserved fish and meat products, wine

Nitrites, Nitrates Nitrites, Nitrates (salts of nitrous acid) – The use of nitrites, nitrates, or

combination shall not result in more than 200 ppm of nitrite, calculated as sodium nitrate, in finished product.

Bacon, cured meat and poultry products

Salt and Sugar (decreases aw) Salt, (iodized, sea salt, kosher salt) – GRAS (when used in accordance with good

manufacturing practice). Sugar (white and brown) – GRAS (when used in accordance with good

manufacturing practice).

Dried salted fish (i.e. salt 5% or more; or water activity

below 0.97 with refrigeration at or below 40°F); butter Jams, jellies, syrups


HACCP PLAN

Step description: Hazards

Safe levels Unsafe levels

Significant risk

Significant risk

controls; targets;

±3σ critical limit

Monitoring and action to keep within critical

limits

Corrective

action, if out of control

Verification of control


THE KITCHEN HACCP TEAM DOES A NACMCF HACCP PLAN WITH RISK MANAGEMENT

STEP CCP Step

Description B,C,P Hazard Analysis Risk Assessment

Hazard Control

Monitoring / Self-Check

Corrective Action (by HACCP team)

Verification and

Improvement

STEP Not sig. sig.

1. 2.

Flow chart the process / recipe. At each step, ask: a.

b. c. d. e.

Is there a B,C,P hazard that can be at a level to make people ill, and is this the correct step to control it? Is it cost effective to control? If yes, what validated control do we use? How does the cook monitor to verify control? If we lose control, what corrective action rules do we apply? How do we verify that we have control?


FOOD OPERATIONS PROCESS RISK CONTROL

•

•

•

Hazard control is the responsibility of the owner / manager / cook.

Risk management begins with assuring that prerequisite programs are effective.

Effective control = real hazards identified by a trained cook following validated controls and using adequate tools and equipment. The cook is given positive reinforcement, and evaluated periodically for improvement.

1. 2. 3. 4. 5. 6.Risk Assessment Operations

Process Step Description

B, C, P Hazard Identification

Exposure Assessment

Risk Characterization

Risk Management

Risk

Communication (Employee procedures

and controls) • • • • •

• • •

•

•

•

• •

•

• •

•

•

•

• Get ready Do_______ Until _____ Check ____ If ________

Then ______ Else_______ Record if __ Clean up Put away

Evidence of a consumer illness / injury, based on epidemiological clinical research evidence

Likely intake of the hazard Controls

associated with the process Frequency

and level of contamination at consumption

Quantity of hazard to cause illness / injury Dose response Percent of people

who will get ill Severity of illness

and cost

Number ill 100,000 persons/year

Risk evaluation Risk

management option assessment Implementation

and management of decisions Monitoring and

review

Risk is never zero Communicate

to the consumer his/her responsibility in risk control


RECIPE FORM

Gp. #

Ingred. #

Ingredients and Specifications

Edible Portion (EP) (weight or volume)

EP Weight %

As served (weight)

Ingredients that are allergenic.

Verification

Prerequisite GMPs and SSOPs are functioning.

Get ingredients and equipment.

1. Pre-preparation Trim fruits and vegetables, meat, poultry, fish, etc. Wash fruits and vegetables.

2. Preparation (Add preservative, pasteurize, mix, etc.) Get food at ____ºF. Do __________ to the food until __________. Take the food (size, volume) and put it in a container. Cook / cool at _____ºF for _____ minutes, until the center is _____ºF. If __________, do __________ (corrective action). Check-record process value.

3. Transport, hold What verified procedure is used?

4. Serve What verified procedure is used?

5. Leftovers What verified procedure is used?

Corrective Actions


FOOD PROCESS FLOW CHARTING Cooking and branching of a recipe process flow

Start

Recipe (Name)

Pre-preparation ↓ 1a. O

Turn oven on. Ti To t

↓ 2a. D

Oven heating. Ti To t

2b. T

Get containers. Go to refrigerator. Ti To t

↓ 3b.

O Weigh ingredients. Ti To t

↓ 4b.

T Go to prep table. Ti To t

↓ 5b.

O Cut/chop ingredients. Ti To t

↓ 6b.

O Add to mixer and mix on #2 speed. Ti To t

6c. O

Combine ingredients for topping. Ti To t

↓ continue 7c.

O Blend, mix, chop. Ti To t

Preparation ↓ 8a. O

Place in convection oven. Ti To t

8b. O

Weigh into pans and add topping. Ti To t

No Yes

8c. I

Is it evenly mixed? Ti To t

↓ 9a. O

Bake at 325°F. Ti To t

↓ No

10a. I

Is the internal temperature at 165°F? Ti To t

↓ Yes 11a. O

Remove from oven. Blast cool to 41°F in #2 refrigerator. Ti To t

↓ 12a. O

Portion into plastic bags. Ti To t

13a. O

Vacuum seal. Ti To t

Industrial Engineering Symbols Number of Times

Ο O = Operate (minimize) 12

í T = Transport (minimize) 2 D D = Delay/Stage (a CCP, minimize) 1 o I = Inspect (optimize after each CCP) 2

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

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

Store ↓ 14a. S

Hold in refrigerator at 30°F. Ti To t

↓ End

Recipe (Name) (2902:11-3)


QUALITY-ASSURED HACCP RECIPE PROCEDURES Recipe Name: Chicken Cacciatore

Portion size (vol./wt.): 1/4 (6 oz.) chicken + 3 oz. sauce

Preparation time: 2 hours

Production style: Combination Number of portions: 100 Prepared by: S. P. Written by: O. P. S. Date: 10/95 Final yield (AS):100 Supervisor: SA/QA by: J. Bell Date: 12/95 Final yield:

Gp. #

Ingred. #

Ingredients and Specifications

Edible Portion (EP) (weight or volume)

EP Weight %

As served (weight)

I 1 Onions, chopped (1/2" x 1") 3.0 lb 1,360.00 g 13.26 2 Mushrooms, cut (1/2 ", caps & stems) 3.0 lb 1,360.00 g 13.26 3 Peppers, green, cut (1/2" x 1") 2.0 lb 907.2 g 8.84 4 Garlic, chopped 6 Tbsp. 85.05 g 0.53 5 Tomatoes, canned, crushed

( 2 - #10 cans) 13.25 lb 6,010.00 g 58.58

6 Oil, vegetable 1/4 cup 54.00 g 0.53 7 Wine, Marsala or Madeira 2 cups 472.00 g 4.60 8 Oregano, crushed 2 tsp. 3.00 g 0.03 9 Salt 1 tsp. 5.50 g 0.05 10 Pepper 1 tsp. 2.10 g 0.02

Total 22.6 lb 10,258.85 g 100.00 22.0 lb Approx. gallons 2.5 gal.

II 11 Chickens, whole (25 - 2¼ to 2½ lb.) 62 lb 40.0 lb Ingredients that could produce possible allergic reactions: Tomatoes, wine Preparation 1. Prepare sauce. Get chopped onions, mushrooms, green peppers and garlic (40°F) from refrigerator. Sauté

the vegetables in vegetable oil for about 10 minutes. Add crushed tomatoes with juice, wine, and seasonings (72°F). Bring sauce to a simmering temperature (205°F, 10 min.).

1a. Hold sauce in bain marie. (165°F, 20 min.) 2. Prepare chicken. Get chicken quarters (40°F) from meat and poultry refrigerated storage area. Remove rib

bones. (45°F, 10 min.) 3. CCP Place quarters, one layer deep in shallow roasting pans. Brown chicken by baking it in a convection

oven at 350°F for 30 min. (>165°F, >15 sec.) 4. Remove pans of chicken from oven. (165°F, 15 min.) Pour off excess liquid. Save for chicken stock. 4a. CCP Cool liquid from 135 to <41ºF, <6 hours, <2 inches deep or <1-gallon container. 5. Cover the chicken quarters with sauce, 155°F, <10 min. (Final temperature 150ºF.) 6. Return the pans of chicken and sauce to convection oven at 300°F and continue baking until all parts of the

chicken reach a temperature of 175°F (about 45 minutes). 7. Check temperature of chicken. If temperature is not 175°F, continue baking. 8. Cover chicken, 175ºF, transfer to 150°F hot holding unit and serve within <2 hours. Hold / Serve 9. Hold / serve chicken >150ºF, <2 hours. For each portion, use either quarter white or dark meat. Chicken

should be accompanied by 3 ounces of sauce (165ºF) (about 3 tablespoons). Leftovers

0. CCP Cool from 135 to <41°F in <6 hours, ≤2 inches deep or <1-gallon container. 1

Process step #

Start food ctr. temp., ºF

Thickest food dimension (in.)

Container size HxWxL (in.)

Cover Yes/No

Temp. on/ around food

End food ctr. temp., ºF

Process step time, hr./min.


CHICKEN CACCIATORE QA RECIPE FLOW Preparation

1. Prepare sauce. Get chopped onions, O mushrooms, green peppers, minced garlic.

Sauté in oil. Add crushed tomatoes, juice, wine, and seasoning. Bring to a simmer.

Ti 40°F To 205°F t 20 min.

1a. Hold in bain marie. D Ti 205°F To 165°F t 20 min.

↓ 2. Get chicken quarters from refrigerator. O Remove rib bones. Ti 40°F To 45°F t 10 min.

↓ 3. CCP Place quarters, one layer deep in O shallow roasting pan. Bake (brown) in

convection oven at 350°F to >165ºF, >15 sec. Ti 45°F To >165°F t 30 min.

↓ 4. Remove pan(s) of chicken from oven. O Pour off excess liquid. Save for chicken

stock. Ti >165°F To 155°F t 15 min.

4a. CCP Cool liquid from 135 to 41ºF in <6 hr., D <2 inches deep or <1-gallon container.

(Save for chicken stock). Ti ≥135°F To <41°F t < 6 hr.

↓ 5. Cover chicken quarters with sauce. O Ti 155°F To 150ºF t <10 min.

↓ 6. Bake at 300°F in convection oven until O chicken reaches a temperature of 175°F. Ti 150°F To >175°F t 45 min.

↓ 7. Check. Is the temperature >175ºF? I If not, continue to cook.

No

↓ Yes 8. Cover and transfer to 150°F hot holding unit. T Ti 175°F To 150°F t 5 min. Hold/Serve ↓ 9. Hold. Serve 1/4 chicken and 3 oz. sauce. D Use within <2 hr. Ti 150°F To 150°F t <120 min. Leftovers ↓ 10. CCP Cool from 135 to <41°F, <6 hr., D ≤2 inches deep or <1-gallon container. Ti 135ºF To <41ºF t <6 hr.


D = Delay I = Inspect O = Operate S = Store T = Transport Ti = Temp. in To = Temp. out t = Time to do the step CCP = Critical Control Point

RECIPE DEVELOPMENT

1. Find an interesting recipe. 2. Do a portion cost. Is the cost OK? 3. Are there allergen problems or

nutritional issues (too few / too many calories per serving)?

4. Do a flow chart of how you will make it in your kitchen with your equipment

5. Make a 1-to-5-gallon batch to check flavor.

6. Calculate weights and weight percents for your batch size (200 gallons?). Cut salt in half.

7. Make a full-size batch. Adjust salt. 8. Serve / sell. Get consumer

feedback. 9. Adjust the ingredients. 10. APC for cooked / pasteurized food

should be <1,000 APC / gram.


STANDARDS OF IDENTITY

USDA Regulates food with >3% raw meat / poultry (>2% cooked meat / poultry)

References: USDA FSIS. May 2003. Food Standards and Labeling Policy Book. Office of Policy Program Development. http://www.fsis.usda.gov/OPPDE/larc/Policies/PolicyBook.pdf. 9 CFR 319. Definitions and standards of identity or composition. CFR website: http://www.gpoaccess.gov/cfr/index.html. Examples of USDA Standards and Labeling

Beef and Gravy: The product contains at least 50% cooked beef. Gravy and Beef: When product contains at least 35% cooked beef, beef is same size as lettering as gravy

in label.) When product contains 25% cooked beef, beef lettering is no larger than one-half size gravy. Gravies: The product must contain at least 25% meat stock or broth, or 6% meat. Mono and diglycerides

allowed in amount of 1% in gravies. For poultry products, see 9 CFR 381.15. These basic guidelines are not intended to be all-inclusive.

Poultry Standards

Name Minimum or Maximum Percentage

Poultry a la King At least 20% poultry

Poultry, Breaded No more than 12% poultry meat Poultry Burgers 100% meat with skin and fat in natural proportions

Poultry Chop Suey At least 4% poultry meat Chop Suey with Poultry At least 2% poultry meat


STANDARDS OF IDENTITY (CONT'D)

FDA Regulates food items that do not contain significant amounts

of meat and poultry.

Items include bakery items, cereals, milk and dairy items, egg products, canned fruits and vegetables, canned fish and shellfish. Fresh fish species must be accurate. Reference: 21 CFR 130 through 169. Standards of identity are defined. CFR website: http://www.gpoaccess.gov/cfr/index.html. Example: Mayonnaise. (21 CFR, Sec. 169.140) (a) Description. Mayonnaise is the emulsified semisolid food prepared from vegetable oil(s), one or both of the acidifying ingredients specified in paragraph (b) of this section, and one or more of the egg yolk-containing ingredients specified in paragraph (c) of this section. One or more of the ingredients specified in paragraph (d) of this section may also be used. The vegetable oil(s) used may contain an optional crystallization inhibitor as specified in paragraph (d)(7) of this section. All the ingredients from which the food is fabricated shall be safe and suitable. Mayonnaise contains not less than 65 percent by weight of vegetable oil. Mayonnaise may be mixed and packed in an atmosphere in which air is replaced in whole or in part by carbon dioxide or nitrogen. (b) Acidifying ingredients. (1) Any vinegar or any vinegar diluted with water to an acidity, calculated as acetic acid, of not less than 2\1/2\ percent by weight, or any such vinegar or diluted vinegar mixed with an optional acidifying ingredient as specified in paragraph (d)(6) of

this section. For the purpose of this paragraph, any blend of two or more vinegars is considered to be a vinegar. (2) Lemon juice and/or lime juice in any appropriate form, which may be diluted with water to an acidity, calculated as citric acid, of not less than 2\1/2\ percent by weight. (c) Egg yolk-containing ingredients. Liquid egg yolks, frozen egg yolks, dried egg yolks, liquid whole eggs, frozen whole eggs, dried whole eggs, or any one or more of the foregoing ingredients listed in this paragraph with liquid egg white or frozen egg white. (d) Other optional ingredients. The following optional ingredients may also be used: (1) Salt. (2) Nutritive carbohydrate sweeteners. (3) Any spice (except saffron or turmeric) or natural flavoring, provided it does not impart to the mayonnaise a color simulating the color imparted by egg yolk. (4) Monosodium glutamate.

(5) Sequestrant(s), including but not limited to calcium disodium EDTA (calcium disodium ethylenediaminetetraacetate) and/or disodium EDTA (disodium ethylenediaminetetraacetate), may be used to preserve color and/or flavor. (6) Citric and/or malic acid in an amount not greater than 25 percent of the weight of the acids of the vinegar or diluted vinegar, calculated as acetic acid. (7) Crystallization inhibitors, including but not limited to oxystearin, lecithin, or polyglycerol esters of fatty acids. (e) Nomenclature. The name of the food is ``Mayonnaise''. (f) Label declaration. Each of the ingredients used in the food shall be declared on the label as required by the applicable sections of parts 101 and 130 of this chapter.


http://www.gpoaccess.gov/cfr/index.html

STANDARDS OF IDENTITY (CONT'D)

BUREAU OF ALCOHOL, TOBACCO AND FIREARMS Regulates alcoholic beverages.

Reference: 27 CFR 1 through 29. Covers standards for alcoholic beverages (Beer, Wine and Distilled Alcohol Products). CFR website: http://www.gpoaccess.gov/cfr/index.html. Example: Sec. 4.21 The standards of identity for wine Standards of identity for the several classes and types of wine set forth in this part shall be as follows: (a) Class 1; grape wine--(1) Grape wine is wine produced by the normal alcoholic fermentation of the juice of sound, ripe grapes (including restored or unrestored pure condensed grape must), with or without the addition, after fermentation, of pure condensed grape must, and with or without added grape brandy or alcohol, but without other addition or abstraction except as may occur in cellar treatment: Provided, That the product may be ameliorated before, during or after fermentation by either of the following methods: (i) By adding, separately or in combination, dry sugar, or such an amount of sugar and water solution as will not increase the volume of the resulting product more than 35 percent; but in no event shall any product so ameliorated have an alcoholic content derived by fermentation, of more than 13 percent by volume, or a natural acid content, if water has been added, of less than 5 parts per thousand, or a total solids content of more than 22 grams per 100 cubic centimeters.

(ii) By adding, separately or in combination, not more than 20 percent by weight of dry sugar, or not more than 10 percent by weight of water. (iii) In the case of domestic wine, in accordance with 26 U.S.C. 5383. (iv) The maximum volatile acidity, calculated as acetic acid and exclusive of sulfur dioxide is 0.14 gram per 100 mL (20 deg.C) for natural red wine and 0.12 gram per 100 mL (20 deg.C) for other grape wine: Provided, That the maximum volatile acidity for wine produced from unameliorated juice of 28 or more degrees Brix is 0.17 gram per 100 milliliters for red wine and 0.15 gram per 100 milliliters for white wine. Grape wine deriving its characteristic color or lack of color from the presence or absence of the red coloring matter of the skins, juice, or pulp of grapes may be designated as "red wine,'' "pink (or rose) wine,'' "amber wine,'' or "white wine'' as the case may be. Any grape wine containing no added grape brandy or alcohol may be further designated as "natural.'' (2) Table wine is grape wine having an alcoholic content not in excess of 14 percent by volume. Such wine may also be designated as "light wine,'' "red table wine,'' "light white wine,'' "sweet table wine,'' etc., as the case may be.

(3) Dessert wine is grape wine having an alcoholic content in excess of 14 percent but not in excess of 24 percent by volume. Dessert wine having the taste, aroma and characteristics generally attributed to sherry and an alcoholic content, derived in part from added grape brandy or alcohol, of not less than 17 percent by volume, may be designated as "sherry''. Dessert wines having the taste, aroma and characteristics generally attributed to angelica, madeira, muscatel and port and an alcoholic content, derived in part from added grape brandy or alcohol, of not less than 18 percent by volume, may be designated as "angelica,'' "madeira,'' "muscatel,'' or "port'' respectively. Dessert wines having the taste, aroma, and characteristics generally attributed to any of the above products and an alcoholic content, derived in part from added grape brandy or alcohol, in excess of 14 percent by volume but, in the case of sherry, less than 17 percent, or, in other cases, less than 18 percent by volume, may be designated as "light sherry,'' "light angelica,'' "light madeira,'' "light muscatel'' or "light port,'' respectively.


http://www.gpoaccess.gov/cfr/index.html

INFORMATION NEEDED FOR LABELING

NUTRITION FACTS LABELNutrition Facts Serving size: Servings Per Container: Amount Per Serving Calories Calories from Fat % Daily Value* Total Fat g % Saturated Fat g % Trans Fat g Cholesterol mg % Sodium mg % Total Carbohydrate g % Dietary Fiber g % Sugars g Protein g

Vitamin A % Vitamin C % Calcium % Iron % *Percent Daily Values are based on 2,000 calorie diet. Your daily values may be higher or lower depending on your calorie needs. Calories 2,000 2,500 Total Fat Less than 65g 80g Sat Fat Less than 20g 25g Cholesterol Less than 300mg 300mg Sodium Less than 2,400mg 2,400mg Total Carbohydrate 300g 300g Dietary Fiber 25g 30g Calories per Gram Fat 9 Carbohydrate 4 Protein 4

1.

2.

3.

Provide a recipe for the item with weights for each ingredient. For brand name items of ingredients with multiple components, provide Nutrition Facts label and ingredient label (canned soups, catsup, sauces, salad dressing). Nutrition can also be supplied by a lab analysis for approximately $900. Provide size of container in which the product will be packed so that the serving size can be calculated.

Common portions

1 T / 15 g: butter 2 T / 30 g: cheese spread, salad dressing, dessert toppings 3 oz. / 85 g: vegetables 4 oz. / 120 g: entrée with sauce, pizza, burrito, sandwiches, salad 8 oz. / 240 grams: milk, juice


VALIDATION

Validation Procedure 1. Recipe 2. Flow the process 3. Get process performance values and critical limits 4. Do challenge tests to validate that performance standards can be met Validation Standards

To validate refrigerated holding processes, use non-pathogenic Listeria innocua and control to <3-log increase.

•

•

•

•

To validate washing food contact surfaces and pasteurization, use non-pathogenic E. coli ATCC 25922 and measure reduction.

Reduction on fingertips after using the toilet, 6 log.

Reduction on fingertips after touching raw meat, fish, and poultry, 2 log. Reduction on raw food contact surfaces, 5 log.

To validate cold holding of ready-to-eat food, use a non-pathogenic Bacillus cereus and control to <3-log increase. To validate cooling, use non-pathogenic Clostridium perfringens and limit to ≤1-log increase.


RETAIL FOOD AMC-HACCP POLICIES, PROCEDURES, AND STANDARDS MANUAL

Table of Contents

Description of the System and Products

1. AMC-HACCP Management Food Safety Policy Responsibility and

Accountability

2. Organization and Personnel

Organization Chart Personnel

3. Facility System Description

Construction, Layout Water Production flow

4. Food Operations Description

Consumer demographics Menu items group HACCP

5. Supplies Supplier HACCP Receiving and storing

6. Food HACCP Production and Distribution

Food production HACCP plans Distribution and service

7. Cleaning and Sanitization Cleaning plan Cleaning GMPs Chemicals

8. Equipment and Maintenance

Maintenance plan Equipment control calibration

9. Pest Control Pest control plan Pest control chemicals

10. Training Program Training

11. QA / QC Thermometer calibration Other instrument calibration Calibration records

12. AMC-HACCP Program Certification


RETAIL FOOD PROCESSES AND CONTROLS Prerequisite / GMP / SSOP Process HACCP

Personal Hygiene (CCP) Employee fingertip nail brush washing and drying for

a 10-6 reduction of bacteria and viruses on fingertips. Environment and Facility (CCP) Water, supply HACCP; chemical and biological

hazard at a safe level. (CP) Insects, rodents, and birds excluded from the facility

through construction and maintenance. (CP) Environment outside the facility is excluded with good

construction, sanitation, and maintenance. There are emergency power sources.

Equipment (CCP) Equipment cleaning: 10-5 reduction of APC on the

equipment surface; thermostat calibration and maintenance.

(CCP) Supplies and material: Contaminated with hazards; suppliers provide their intervention strategy; expected level of biological, chemical, and physical hazards.

Receiving (CP) Just-in-time delivery of raw food: fresh <40ºF or

frozen. Pathogenic substances will be reduced to an acceptable risk by washing, pasteurization, or removal. Target values for raw foods are:

Salmonella spp.: <10 / gram Listeria monocytogenes: <100 / gram Staphylococcus aureus: <100 / gram Clostridium perfringens: <100 / gram Bacillus cereus: <100 / gram Clostridium botulinum: <1 / gram

Chemical: safe level Physical: <1/16 inch

(CCP) Just-in-time delivery of ready-to-eat food <40ºF. Target values for ready-to-eat foods are:

< 1 E. coli or Salmonella / 100 grams <1,000 S. aureus /gram <10,000 B. cereus, and C. perfringens vegetative cells

/ gram <10 C. botulinum vegetative cells / gram Undetectable viruses and parasites Chemical: safe level Physical: <1/16 inch

(CCP) Avoid biological, chemical, and physical contamination at receiving.

(CCP) Damaged packages, cans, and infested packages stored separately for return to supplier.

Storage (CP) Label food containers with receiving date; store food 6

inches off floor. (CP) Short-term frozen storage <10ºF; long-term 0 to –

20ºF. (CCP) Aerobic, refrigerated, raw food spoils safe or is made

safe by washing, 10-2 reduction, or pasteurization, 10-5 reduction.

(CCP) Spoilage bacteria inhibit S. aureus, C. botulinum, toxin production in raw meat and poultry.

(CCP) Refrigerated, ready-to-eat food is used before there is time and temperature for 3-log increase of L. innocua or 3-log increase of B. cereus to multiply.


RETAIL FOOD PROCESSES AND CONTROLS (CONT'D) Food Process HACCP

Pre-preparation (CP) Use oldest ingredients first (FIFO). (CCP) Cook from the frozen state or thaw at room temperature

or colder until the center is 35 to 38ºF. (CP) Keep food temperature <55ºF during preparation. (CCP) Double wash fruits and vegetables in water, 10-2

reduction or use thermal surface pasteurization, boiling water, 15 seconds, 10-5 reduction.

(CCP) Do not cross-contaminate raw, unprocessed and ready-to-eat foods.

Preparation Chemically preserved: Nitrate, acid, salt, sugar jams, dressing,

sausage, candy, salt, fish. (CCP) Ferment foods such as cheese, buttermilk, yogurt, wine,

liquor, sauerkraut, cider, vinegar, etc. with controlled starter culture and validated HACCP procedures.

(CCP) Additives: Use according to CFR. (CCP) Smoking: Prevent growth of S. aureus to <3-log

increase. (CCP) Acid control: Jam, dressing, condiments. Control salmonellae in unpasteurized food with pH <4.1. Control Clostridium botulinum in pasteurized food with pH

<4.6. (CCP) Heat to >130ºF, fast enough to prevent >3 log increase of

S. aureus. (CCP) Pasteurize raw, high-water-activity meat, fish, and

poultry: 5D salmonellae (z = 10ºF D140 = 1.73 minutes) to achieve <1 Salmonella per 100 grams.

(CCP) Sterilize: 9D C. botulinum, z = 18ºF; D210 = 400 minutes. (CCP) Hot hold surface and center >130ºF with controlled Rh

>90% (CCP) Cool center, 120 to 55ºF, 6 hours; 41ºF, <14.2 hours for

<1-log increase of C. perfringens.

(CCP) Mix cold salads with precooled ingredients to 50ºF to prevent production of S. aureus toxin.

(CCP) Allergen control: Do not add any ingredients that are not on the recipe ingredient list.

(CCP) Cold hold ready-to-eat food (except fish) at <40ºF until spoiled or to <3-log increase of B. cereus.

Package -- transport -- serve (CCP) Pasteurized food hold >130ºF or <40ºF, or at any time-

temperature that limits vegetative forms of spore pathogens to multiply to <3-log increase of C. perfringens or B. cereus between production and consumption.

(CP) To retain nutrients, hot hold for service, <30 minutes. NOTE: Hot liquids >170ºF will burn skin in 1 or 2

seconds. (CCP) Protect cold, ready-to-eat food from hazard

contamination. Leftovers (CCP) Do not add fresh food to old food for allergen control

and prevention of cross-contamination. NOTE: Reheating is not used as a hazard control,

because it will not control toxins, poisons, and physical hazards. Once cooked / disinfected, the process must be controlled to prevent the ready-to-eat food from becoming hazardous.

Consumer (CCP) Take-out package for the consumer <2 inches thick for

rapid cooling. Label, "Consume in 4 hours, or begin cooling as soon as possible to 55ºF in less than 14.2 hours. Do not cool food in a container in a bag, because this blocks heat transfer. Remove the bag."

(CCP) Label packages for allergenic ingredients. Answer consumer allergy questions about food ingredients.


HACCP = MANAGERIAL EMPOWERMENT of the chef and kitchen staff to control the hazards


Company Name Date

HACCP TEAM MONTHLY MEETING REPORT

HACCP Team __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________

Initial if present (leader)

Suggested topics 1. Verification of effective HACCP program:

self-inspection, corrective action, customer comments, training, government correspondence, improvements, changes to manual

2. Education 3. Other

Topics Follow-up

NEXT MEETING: ______________________________ HACCP Team: We affirm that we are capable of preparing and serving safe food. _____________ Management review, comments _______________________ Signature ____________________ Process authority review, comments: ___________________ Signature ____________________


CORRECTIVE ACTION REPORT(1)

Person completing report______________________ Date _______________

Critical limit corrective action Quality corrective action

Description of the problem. What was done immediately to take care of the problem? What was done with any questionable food?

Elimination. It must include what action was taken to put process back into control according to Corrective Action plan.

Verification that process was back in control. Show data that the critical control point was under control after correction: Example: Take data at the CCP for a time following corrective action to PROVE that problem was fixed.List measures to prevent recurrence. Examples: Training in use of nail brush, new thermometer, fans added to refrigerator, food panned <2 inches deep.Reviewed by ________________________________ Date _______________

(1) Ref. USDA 9 CFR 417.3.A


SUMMARY

New process innovation is crucial to the retail food industry. The USDA and FDA do not do new process hazard control development. The industry does.

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Food ingredients from the land and water farm are contaminated with biological, chemical, and physical hazards that must be controlled.

The HACCP process analysis method is the basis for safe food development / innovation.

All processed foods can be categorized into five process groups.

The recipe is the basic process control document.

Process control and stability require Active Managerial Control, a food safety, HACCP-based policies, procedures, and standards manual, and empowerment of employees to do tasks correctly the first time and to control the hazards.


the haccp recipe for process innovation ... haccp recipe for process innovation haccp recipe...

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