UNIFICATION OF RETAIL AND PROCESS HACCP · Double wash fruits and vegetables (2-log reduction) or blanch ... lettuce and coleslaw salads; fruit salads; ... Flow Chart HACCP Plan

8/11/2005 IAFP05-unify-HACCP 1

UNIFICATION OF RETAIL AND PROCESS HACCP

PRESENTED AT IAFP ANNUAL MEETING

BALTIMORE, MARYLAND, AUGUST 17, 2005

O. Peter Snyder, Jr., Ph.D.Hospitality Institute of Technology and Management

670 Transfer Road, Suite 21ASt. Paul, Minnesota 55114 USA

TEL 651 646 7077 FAX 651 646 [email protected] http://www.hi-tm.com


THE RAW FOOD CONTAMINATION PROBLEM

1370


FOOD MICROBIOLOGICAL CONTAMINATION

30WaterGiardia lamblia, Norovirus

33-46Raw seafoodVibrio spp.

49; 48; 46Raw pork; Raw milk; Raw vegetablesYersinia enterocolitica

26; 30Fresh potatoes; Fresh radishesListeria monocytogenes

43-63; 100Raw ground beef; Raw riceBacillus cereus

1.5-3.7Raw beef/pork/poultryEscherichia coli O157:H7

45-64Raw chicken and turkeyCampylobacter jejuni

39-5Raw pork and chickenClostridium perfringens

73; 13-33; 16Raw chicken; Raw pork; Raw beefStaphylococcus aureus

40-100; 3-20; 16Raw poultry; Raw pork; Raw shellfishSalmonella spp.

Percent ContaminatedSourceMicroorganism

HUMAN MICROBIOLOGICAL CONTAMINATION

Throat and skinStreptococcus Group A

Skin, nose, boils and skin infections

Staphylococcus aureus

VomitNorovirus

FecesShigella spp., Hepatitis A, norovirus, E. coli, Salmonella spp., Giardia lamblia

Percent ContaminatedSourceMicroorganism

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

MIEHA-11-04;lh78:fd&hum-cont


ESTIMATED ANNUAL FOODBORNE ILLNESSES


"CHEFS" DO PROCESS INNOVATIONTHEY ALSO DO RISK MANAGEMENT AND DESIGN THE PROCESS

TO REDUCE THE SIGNIFICANT HAZARDS TO AN APPROPRIATE LEVEL OF PROTECTION (ALOP)

• Food preparers must know the expected hazards in their kitchens,the amount / size and tolerable limits, and decide if control is necessary.

• Food preparers validate process controls that prevent, eliminate, or reduce the hazards to a tolerable level.

Decide if control is necessary for an ALOP.

What it will cost to control the risk.

Assuming no control – the cost per year.

What is the probability of illness?

Risk Management

Control Analysis

Risk Analysis

Hazard Analysis

Food preparers make the food safe through control of the processes, monitoring, and corrective action.

• Pasteurizing food• Hot holding• Fermentation, acid, aw, Rh, Eh• Cooling, cold holding

• Purchasing• Prevention of cross-contamination• Fingertip washing• Fruit and vegetable washing


HACCP REFERENCE DOCUMENTS

U.S. Department of Health, Education, and Welfare; Food and Drug Administration; Public Health Service. 1971. Proceedings of the 1971 National Conference on Food Protection. Sponsored by American Public Health Association. Denver, CO.

The Pillsbury Company Research and Development Department. 1973. Development of a Food Quality Assurance Program and the Training of FDA Personnel in Hazard Analysis Techniques. 4th Printing (1977). The Pillsbury Company. Minneapolis, MN.

International Commission of Microbiological Specifications for Foods (ICMSF). 1980 through 2002. Microbial Ecology of Foods / Microorganisms in Foods (Seven volumes). Academic Press; Blackwell Scientific Publications; Blackie Academic & Professional; Kluwer Academic Plenum Publishers.

NACMCF. 1998. Hazard analysis and critical control point principles and application guidelines. J. Food Prot. 61(9):1246-1259. [www.cfsan.fda.gov/~comm/nacmcfp.html] (1992. Internatl J. Food Microbiol. 16:1-23.)

NACMCF. 1998. Principles of risk assessment for illness caused by foodborne biological agents. J. Food Prot. 61(8):1071-1074.

Institute of Food Technologists. 2004. Managing food safety: Use of performance standards and other criteria in food inspection systems. Chicago, IL. [http://www.ift.org/pdfs/scitech/managing_food_safety.pdf]

International Organization for Standardization (ISO). 2004. Food safety management systems –Requirements for organization throughout the food chain. Draft International Standard ISO/DIS 22000. [ISO website: http://www.iso.org/iso/en/ISOOnline.frontpage]


GOVERNMENT AGENCIESINVOLVED IN SAFE FOOD

27 CFR Bureau of Alcohol, Tobacco and Firearms

Alcoholic beveragesBATFVessel sanitation programCruise ship food safetyCDC (DHHS)FDA Food Code, state and local regulationsRetail food safetyFDA (DHHS)

50 CFR National Marine Fisheries ServiceFish inspectionNOAA (DOC)

9 CFR Animal and Animal ProductsMeat and poultry productsUSDA (FSIS)

Pasteurized Milk Ordinance (PMO)Milk and dairy productsFDA (DHHS)

National Shellfish Sanitation Program (NSSP)

ShellfishFDA (DHHS)

21 CFR 123 Fish and fishery productsFish and fish productsFDA (DHHS)

21 CFR 110 Current good manufacturing practice in manufacturing, packing, or holding human food

21 CFR 113 Thermally processed low-acid foods packaged in hermetically sealed containers

21 CFR Acidified foods

Process, products that contain less than 3% meat and poultry

FDA (DHHS)

RegulationCategoryAgency


GOVERNMENT PROCESS "CONTROLS" VS. HACCP PERFORMANCE STANDARDS

2-5-log reduction.NoneNoneNoneNoneFruit and veg. wash / blanch

6-log reduction.Visually cleanVisually cleanVisually cleanVisually cleanCleaning feces from fingers

None. Past. assures safety.

41ºF40ºF45ºF40ºFCold raw food storage

<3-log increase B. cereus41ºF 40ºF45ºF40ºFCold holding

<1-log increase C. perf.135 to 70ºF, 2 hr., 70 to 41ºF, 4 hr.; total 6 hr.

NoneNone<1 log growth C. perf.

Cooling

<1-log increase C. perf.135ºF all except roast beef 130ºF

140ºF140ºF140ºFHot hold

Supplier certifies fully cooked or 5D center reduction.

Hamburger 155ºF, 15 sec.; Roast beef 130ºF, 112 min,; Poultry 165ºF, 15 sec.

NoneNoneRed meat, 6.5D; Poultry, 7D

Cooking / pasteurization

If pasteurized, pH <4.6, <1-log increase C. bot. If raw, pH <4.1, <1-log increase Salmonella.

pH <4.6 (changing to Temperature Control for Safety, TCS)

pH <4.6pH <4.6pH <4.6Acidified food

None. Past. makes safe. NoneNoneNoneNonePre-preparation

2-5-log reduction.Visually cleanVisually cleanVisually cleanVisually cleanCleaning food contact surfaces

HACCP Perform. Stnds.FDA Food CodeFDA FishFDA ProcessUSDAItem


HACCP IS AN ANALYTICAL PROCEDURETO SET FOOD PROCESS SAFETY CRITERIA

• Food Safety Objective (FSO)

• Appropriate level of protection (ALOP)

• Ingredient specifications, to prevent high levels of incoming hazards

• Risk analysis, to determine significant hazards

• Control, to reduce significant hazards to an ALOP (illness per 100,000; deaths per 1,000,000)

• Monitoring and corrective action, to achieve process stability and capability

• Certification

DISTRIBUTION

Contamination (baseline): • Biological• Chemical• Physical

ConsumerProcessor / kitchenFood from the farm

EXAMPLE USING PROCESS SAFETY CRITERIA:Cook for a 5D reduction of Salmonella to get <1 Salmonella / 100 g

(Control measure) (Performance criterion) (Food safety objective)


THE HACCP TEAM DOES A NACMCF HACCP PLAN WITH RISK MANAGEMENT

Not sig sigSTEP

Verification and

Improvement

Corrective Action (by

HACCP team)

Monitoring / Self-Check

Hazard Control

B,C,P Hazard Analysis / Risk Assessment

CCP Step Description

STEP

1. Specify ingredients and flow chart the process / recipe.2. At each step, ask:

a. 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?

b. If yes, what validated control do we use?c. How does the cook monitor to verify control?d. If we lose control, what corrective action rules do we apply?e. How do we verify that we have control?


FOOD OPERATIONS RISK CONTROL MANAGEMENT

1904-ov&risk:food-op-haz-cont

• Risk = the likelihood of a hazard injuring a customer x the severity• Risk management is the responsibility of the owner / manager / chef (not regulatory

officials) to provide an Appropriate Level of Protection (ALOP) to their customers. Food liability insurance is for the residual low probability of an unanticipated event.

• Effective control of significant hazards is when a trained cook follows validated procedures to control hazards for an ALOP. The cook is then given positive reinforcement, and processes are evaluated periodically for improvement.


POTENTIAL HAZARDS IN THE FOODCHEMICALPoisonous SubstancesToxic plant materialIntentional additivesChemicals created by the processAgricultural chemicalsAntibiotic and other drug residues Unintentional additivesEquipment leachingPackaging leachingIndustrial pollutantsHeavy metalsRadioactive isotopesAdverse Food Reactions(food sensitivity)Food allergensFood intolerancesMetabolic disorderPharmacological reactionsIdiosyncratic reactionsAnaphylactoid reactions

BIOLOGICALMicroorganisms and their ToxinsBacteria: vegetative cells and sporesMolds (mycotoxins, e.g., aflatoxin)Yeasts (Candida albicans)Viruses and rickettsiaParasitesFish and shellfish as sources of toxic compoundsPests, animals (birds, insects and rodents) as carriers of pathogens Filth from insects, rodents, and any other unwanted animal parts or excreta

PHYSICALHard Foreign ObjectsGlassWoodStonesMetalPackaging materialsBonesBuilding materialsPersonal effectsFunctional HazardsParticle size deviationPackaging defectsSabotageChoking / Food Asphyxiation HazardsPieces of food Thermal HazardsFood so hot that it burns tissue


FOOD HAZARDS AND SAFETY OBJECTIVES


THE UNIT AS A FOOD

PROCESS SYSTEM

Food HACCP ProcessesDouble wash fruits and vegetables (2-log reduction) or blanch

(5-log reduction)Fermentation (5-log reduction)Acid food pH <4.6 (spore) or <4.1 (Salmonella)Pasteurize (5-log reduction)Hot hold <1-log increase Clostridium perfringensCool <1-log increase Clostridium perfringens (meat),

Bacillus cereus (starch, milk, and vegetables)Cold hold (food bank ≤40°F) <3-log increase Bacillus cereus

Prerequisite HACCP ProcessesSafe water (<1 fecal coliform)Food supplier hazard control for safe, raw foodChemical (separation)Physical hazards in food (<1/16 inch)Equipment performance standard calibration

(temperature, speed, air flow)Double fingertip wash (6-log reduction)Wash food contact surfaces (2-to-5-log reduction)


PRODUCTS CAN BE GROUPED BY HACCP PROCESSHazards, Critical Controls, Limits (USDA HACCP, 9 CFR 417)

Shelf lifeHACCP Process

Commercially sterile, shelf stable. canned meat, fish, poultry; canned dairy products, canned vegetables

Fully cooked, with inhibitors to make shelf stable. marinara sauce; pie fillings; smoked fish; canned, low-pH fruits and vegetables; dry cereals, pasta

Fully cooked, not shelf stable. hot or cooled, refrigerated ready-to-eat food; meat, fish, poultry; fruits and vegetables, dairy

Not fully cooked, with inhibitors to make shelf stable.pepperoni; salami; ham; salted, dried fish; cheese; salad dressing; beer; wine

Not fully cooked, not shelf stable. Rare meat, fish, poultry; eggs, vegetables

Not heat treated, with inhibitors to make shelf stable. flour, nuts, salt, sugar, honey, spices and herbs, corn meal, oil and lard

Not heat treated, with secondary inhibitors, not shelf stable.corned beef

Not heat treated, not shelf stable. sashimi; lettuce and coleslaw salads; fruit salads; sprouts; yogurt; sauerkraut; kimchee; salsa

<14 daysI

<14 daysII

>2 years (chem. spoil)

III

<14 daysIV

>2 years (chem. spoil)

V

Hot >125ºF NTLCold 14-90 days

VI

>5 yearsVII

>5 yearsVII


CONTROL DOCUMENTS FOR RETAIL HACCPFood Process HACCPPre-preparation

Physical hazardsChemical hazardsAllergensThawingFruit and vegetable washingServing raw food

PreparationSalad and hors d'oeuvresPasteurizationHot holdingCoolingCold holdingReheatingLeftovers

Serving foodFood removed from

temperature control

Reuse of packaged foodCommunicating food safetyTake-out foodCatering

Prerequisite ProcessesPersonal hygiene

Employee illness reportingHand washing

After toiletAfter touching raw food

Cleaning, maintenance, and pest control

FacilitiesEquipment and

warewashingSupplies

Source of supplyIngredientsSupplier safe vs. cook

made safe

Receiving inspection Storage: ambient,

refrigerated, frozen

Control of physical, chemical,

and biological contamination

PrefaceLogReassessmentSelf-inspection and HACCP team reports

Operations Description (Plan Review)System descriptionOrganizationEnvironment (picture)Facilities (plan)Equipment (list)Menu HACCP (processes)

AMC-HACCP ManagementFood safety policyResponsibility and accountabilityHACCP team / QC

Self-inspectionCorrective actionTraining

EmergenciesFood security / sabotage

Food Safety Manual Recipe

HACCP PlanFlow Chart


HACCP FOOD SAFETY PLAN (TRAINING) MANUALFood Process HACCPPre-preparationPhysical hazardsChemical hazardsAllergensThawingFruit and vegetable washingServing raw foodPreparationSalad and hors d'oeuvresPasteurization / sterilizationIngredients to extend shelf

life Hot holdingCoolingCold holdingLeftovers / reprocessing Distributing / serving foodCommunicating safe

handling

Prerequisite ProcessesPersonal hygieneEmployee illness reportingHand washing

After toiletAfter touching raw food

Cleaning, maintenance, and pest controlFacilities, EnvironmentEquipment and

warewashingSuppliesSource of supply

IngredientsSupplier safe vs. cook

made safeReceiving inspection Storage: ambient,

refrigerated, frozenControl of physical,

chemical, and biological contamination

PrefaceLog of changesReassessment

Operations Description System descriptionOrganizationEnvironment (picture)Facilities (plan)Equipment (list)Menu HACCP (processes)

AMC-HACCP ManagementFood safety policyResponsibility and

accountabilityHACCP team / QC

Self-inspectionCorrective actionTraining

EmergenciesFood security / sabotage


PREREQUISITE PROCESSDOUBLE HAND WASHING WITH NAIL BRUSH

Dept.: __________ Person responsible: ________________ Effective date: _______ Process: To double wash fingertips and hands to reduce fecal pathogens 6 logMaterials: Water 2 gallons / minute; 75 to 110ºF; soap; paper towel

STANDARDS AND OPERATING PROCEDURE

Apply 5 ml detergent to the fingernail brush.

With water at 2 gallons per minute, brush and lather, particularly fingertips and fingernails, 3-log reduction.

Second wash.

Rinse and further dilute pathogens for 2-log reduction.

Dry hands using paper towel(s), 1-log reduction.


QUALITY-ASSURED HACCP RECIPE PROCEDURESEdible

(wt.)Ingred. # As Served (weight) Portion

( vol.)EP Weight %Ingredients and SpecificationsGp. #

Ingredients that could produce possible allergic reactions: Prerequisite ProceduresSSOPs / GMPs. Control chemicals. Remove physical hazards from food. Double wash fingertips / personal hygiene (6-log reduction). Sanitize food contact surfaces, 5-log reduction. Train. QC. Buy food and store.Pre-preparation1. Get food for recipe, <3-log increase L. monocytogenes.2. Thaw <70ºF, 1-log increase L. monocytogenes. 3. Do pre-prep. No time-temperature hazard. No CCP.

Preparation4. CCP. If making salad with uncooked ingredients, double wash all fruits and vegetables to reduce

vegetative pathogens 2 log or blanch, ≥5-log reduction of Salmonella..5. CCP. If hot food, cook for 5-log Salmonella reduction (155ºF, 15 seconds).

Hold / Serve6. Hot hold, transport, serve. <1-log increase C. perfringens (>125ºF, 90% Rh).

Leftovers7. CCP. Cool to prevent >1-log increase of C. perfringens (135 to 41ºF, <14 hr.; <2 in. deep or

1- gal. pot).8. Cold hold, <3-log increase B. cereus. If making cold mixed salad, get all ingredients <50ºF before mixing.9. Hold leftovers <3-log increase B. cereus (<7 days 41ºF and reheat to 165ºF, 15 sec.).

10. CCP. For allergen control, do not combine / mix leftovers.

Process step time, hr./min.

End food ctr. temp., ºF

Temp. on / around food

Cover Yes/NoContainer sizeHxWxL (in.)

Thickest food dimension (in.)

Start food ctr. temp., ºF

Process step #


CHICKEN CACCIATORE HACCP RECIPE

Preparation1. 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 / Serve9. Hold / serve chicken >150ºF, <2 hours. For each portion, use either 1/4 quarter white or dark meat. Chicken should be accompanied by 3 ounces of sauce (165ºF) (about 3 tablespoons).Leftovers10. CCP Cool from 135 to <41F in <6 hours, ≤2 inches deep or <1-gallon container. Ingredients that could produce possible allergic reactions: Tomatoes, wine

Process step time, hr./min.

End food ctr. temp., ºF

Temp. on / around food

Cover Yes/NoContainer sizeHxWxL (in.)

Thickest food dimension (in.)

Start food ctr. temp., ºF

Process step #


CHICKEN CACCIATORE HACCP RECIPE FLOW

S=StoreD=DelayT=TransportI=InspectO=operate


CHICKEN CACCIATORE HACCP PLAN


PROCESS VALIDATION "APPROVAL'JOURNAL PEER-REVIEWED RESEARCH REPORT

AbstractIntroductionWhat is the process; what is the hazard; and what is the purpose of the report?MethodsHow were samples prepared?What microorganisms were used and source?What additives were used?How was the test conducted and controlled?How were the results measured?ResultsWhat were the data from the study, and how uniform were results?DiscussionDiscuss results in terms of the purpose of the studyConclusionsWas or was not the hazard effectively controlled?Summary


THE TEST OF AN EFFECTIVE HACCP PROGRAM

Say to the manager, "Show me your Food Safety Management (HACCP) Manual."

• Go to an employee producing food and ask, "What are you preparing, and why is it safe to eat?

• The employee should answer with the hazard and control information for that recipe in the manual.

"The hazards are ____________.""We do the following to control / reduce the hazards to an Appropriate Level of Protection (ALOP)."

Documents

UNIFICATION OF RETAIL AND PROCESS HACCP · Double wash fruits and vegetables (2-log reduction) or blanch ... lettuce and coleslaw salads; fruit salads; ... Flow Chart HACCP Plan