HACCP

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HACCP

• Food Safety Plan

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Definition of HACCP

• A systematic approach to construct a food safety
  program designed to reduce the risk of foodborne
  hazards by focusing on each step of the food
  preparation process from receiving to service.

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Controlling Hazards ? Safe Food

• Hazards involving food preparation, i.e.,
  improper cooking of beef, chicken, eggs, etc.
• Hazards that affect all foods, such as poor
  personal hygiene.

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Controlling Food Preparation Hazards

• Identify Critical Control Points (CCPs)
• Cooking, cooling, hot/cold holding, reheating
• Control/prevention
• Time and temperature

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Controlling All Other Hazards

• Develop and Implement Standard Operating
  Procedures (SOPs).
• All activities except food preparation
• Receiving, cleaning and sanitizing equipment and
  utensils, food storage, etc.

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Step 1 Develop and Implement SOPs

• Stepby-step written instructions for food
  service tasks that affect food safety

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Sample SOPs

• Cooking Potentially Hazardous Foods (PHF)
• Cooling PHF
• Holding Hot and Cold PHF
• Date Marking, Ready-to-eat (RTE), PHF
• Personal Hygiene
• Reheating PHF
• Receiving Deliveries
• Storing and Using Poisonous or Toxic Chemicals
• Using Suitable Utensils When Handling RTE Foods
• Washing Fresh Fruits and Vegetables
• Handwashing

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SOPs for your use

• USDA is developing SOPs, the final versions
  posted at
• www.nfsmi.org
• Iowa State Universitys Safe Food resources
• www.schoolhaccp.org/

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Step 2 Classify all Menu Items using the
Process Approach

• Categorizes food preparation into three broad
  categories based on how many times each menu item
  moves through the temperature danger zone
  (between 41F and 135F).

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The Division of Foods is Based on Complete
Trips through the Temperature Danger Zone
140oF
2
1
0
3
1
41oF
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Step 2Classify all menu items

• The Process Approach categories
• Process 1 No Cook
• Process 2 Same Day Service
• Process 3 Complex Food Preparation

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Process 1 No Cook

• The menu item does not go completely through the
  danger zone in either direction.
• Examples fresh fruit and vegetables, salad bar
  items.

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Process 2 Same Day Service

• The menu item takes one complete trip through the
  danger zone (going up during cooking) and is
  served.
• Or
• Anything that is cooked and served in the same day

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Process 3- Complex Food Preparation

• The menu item goes through both heating and
  cooling, taking two or more complete trips
  through the danger zone.
• These items are cooked, cooled and reheated.

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Step 3 Identify and document control measures
and critical limits

• Control measures prevent, eliminate, or reduce
  hazards.
• Control measures include SOPs as well as the CCPs
  (cooking, cooling, reheating, holding) and the
  critical limits (times and temperatures)
  established in each of the three processes.

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Example - Chicken

• Process 1
• We purchase pre-prepared chicken salad and hold
  it cold to be served on the salad bar or on
  sandwiches.
• Process 2
• We cook frozen or fresh chicken and serve it the
  same day.
• Process 3
• We cook frozen or fresh chicken, cool it and use
  it to make chicken salad from scratch or
• We cook frozen or fresh chicken, serve it the
  same day, have leftovers, cool it down and on
  another day we heat it up and serve it.

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Lets Practice!

• Garden Salad
• Grilled Ham Cheese
• Leftovers
• Garlic Breadsticks
• Sub Sandwich
• Peach Cobbler
• Spaghetti
• Pasta Salad

• Hot Pocket
• Salsa
• Tortilla Chips
• Burrito (pre-prepared)
• Hamburger
• Sliced Tomato Lettuce
• Canned Pears
• Chili

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CCP for Process 1 No Cook

• Cold holding or limiting time in the danger zone
  to inhibit bacterial growth and toxin production.
• (Food that is held at room temperature for four
  hours must be discarded.)

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CCPs for Process 2 Same Day Service

• Cooking to destroy harmful bacteria and other
  pathogens.
• Hot holding or limiting time in the danger zone
  to prevent the outgrowth of spore-forming
  bacteria.

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CCPs for Process 3 Complex Food Preparation

• Cooking to destroy harmful bacteria other
  pathogens.
• Cooling to prevent the outgrowth of spore-forming
  bacteria.
• Hot and cold holding or limiting time in the
  danger zone.
• Reheating for hot holding.

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CCPs and their Critical Limits

• Each CCP (cooking, cooling, reheating, holding)
  must include time and/or temperature limits.
• For example, when cooking chicken, the
  time/temperature limit is 165F for 15 seconds.

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Calibrating a Bi-Metallic Stemmed Thermometer

• When to Calibrate
• Daily
• After extreme temperatures
• After bumping or dropping
• How to Calibrate
• Insert stem in ice water bath (without touching
  bottom or sides)
• Adjust nut until needle indicates 32oF (freezing
  point)

Calibration Nut-----gt
Dimple-----gt
Ice Water Bath -----gt
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Cooling Requirement

• Two-stage Method
• (6 Hours)
• (i.e., products cooked day before)
• 70oF within 2 hours
• 41oF within 4 more hours
• Take temperatures at 2 and 6 hour intervals to
  make sure that temperatures were reached.
• Reheat above 165oF if food has not cooled to 70oF
  in 2 hours or 41oF in 6 hours.
• Discard if more than 70oF after 2 hours or more
  than 41oF after 6 hours.

• One-stage Method
• (4 Hours)
• (i.e., leftovers)
• 41oF within 4 hours
• Take temperature after 4 hours to make sure that
  temperature was reached.
• Reheat above 165oF if food has not cooled to 41oF
  in 4 hours.

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Documentation

• You must document CCPs (heating, cooling,
  hot/cold holding, reheating) and Critical Limits
  (temperatures/times) for each menu item you
  sorted into the three processes.
• HOW? Recipes and SOPs

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Where to Record Process Number

• Write the process number on each recipe

• Make a poster for each process and list the foods
  that belong in each

• Write the
• process
• number on
• the menu

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Recipes

• Should include final and holding temperatures.
• USDA Quantity Recipes for School Food Service
• www.nfsmi.org/Information/school_recipe_alpha.htm.

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Bridging the Gaps

• SOPs for menu items that do not have recipes,
  cooling foods and reheating leftovers.

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Step 4 Monitoring

• Control measures (i.e., cooking times
  temperatures) must be monitored and documented in
  writing.
• How?
• When and how often?
• Who is responsible for monitoring?

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Monitoring Example

• Cold foods must be kept at 41F or below.
• The temperature of the refrigerator must be
  recorded on a refrigeration temperature
  monitoring chart at least two times daily to make
  sure the temperature is 41F or below.

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Step 5 Corrective Actions

• Must be carried out immediately whenever a
  critical limit is not met.
• Examples
• Continue to heat to required temperature
• Rejecting food delivery
• Discarding food held too long without temperature
  control

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Corrective Action Examples

• The temperature in the refrigerator is above 41F
• SOP
• The equipment must be checked. The thermometer
  used to record the temperature should be
  calibrated regularly and checked to see if it is
  working properly.
• Any PHF should be temped. If unable to determine
  if the food has been in the danger zone for less
  than 4 hours, discard.

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Corrective Action Example

• The freezer temperature is 49F when you arrive
  to work on Monday morning
• SOP
• Take temperature of food in freezer
• Any food above 41F must be discarded
• Any foods below 41F shall be transferred to a
  refrigerator immediately and used within 2-3 days
  (never re-freeze)

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Step 6 Keep Records

• Food Safety Plan Training
• Monitoring Temperatures of food, equipment food
  storage areas and equipment
• Calibration Records
• Corrective Action

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Examples of Required Documentation

• SOPs
• Time and Temperature charts
• Corrective Action records (when applicable)
• Verification/Review records
• Calibration records
• Training logs
• Receiving logs

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Step 7 Review Revise Food Safety Program
Periodically

• Ongoing monitoring
• Periodic at least yearly to reflect facility
  or equipment changes (i.e., new equipment and
  menu items)

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Factors Contributing to Your Success

• Facility
• Equipment
• Managers
• Employees

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All Employees should have

• Initial food safety training
• On-going food safety training
• Record of training kept by district
• Training standards monitored daily by manager
• Review of SOP guidelines at least yearly

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HACCP Program Requirements

• A written plan at each site that includes
• Documenting menu items in the appropriate
  process category.
• Documenting Critical Control Points of food
  production.
• Monitoring
• Establishing and documenting corrective action.
• Recordkeeping
• Reviewing and revising the overall food safety
  program periodically.