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Food Service and HACCP… “Perfect Partners for Food Safety”
Objectives
• HACCP and its Purpose • How It Works • HACCP Principles • Application to Food Service • Process HACCP
Definition of HACCP
A systematic approach to the identification, evaluation, and control of food safety hazards - NACMCF, 1997
Origin of HACCP
• First used by Pillsbury and NASA in the 60’s.
• Alternative to end item product testing.
• Organoleptic inspection did not guarantee safety.
• Cannot test 100% of the product.
• 1990s embraced by NACMCF, industry and regulatory agencies.
HACCP – What It Is
• Hazard Analysis & Critical Control Points • Is a management tool used to protect the food supply against biological, chemical and physical hazards • Is preventive, not reactive
HACCP – It’s Purpose
• It is designed to prevent, eliminate and/or reduce, to an acceptable level, all hazards which have a reasonable likelihood of occurrence.
• Hazards may include – foodborne illnesses – physical hazards/injuries
Current U.S. Foodborne Illness Data (Mead et al., 1999)
• 76 million illnesses • 325,000 hospitalizations • 5,000 deaths
Biological Hazards Percentage of Foodborne Illness Attributable to Known Pathogens
Bacteria 30% Parasites 3% Viruses 67%
Where Is HACCP Used?
• Global standard for food safety.
• Being applied throughout food industry.
• Mandatory for low acid canned foods (lacf), seafood, red meat, poultry, and citrus juices.
• HACCP for dairy, eggs, sprouts, sushi, retail and restaurant programs are in various stages of development.
HACCP basically is …
• Determining what needs to be controlled and how to control it • Monitoring what’s important • Determining what can go wrong and how to “fix it” • Making sure those actions are being done
How Does HACCP Work
• To be successful must have support and commitment of management.
• Based on seven principles.
How Does HACCP Work
• Still need sanitation and GMPs.
– Is not a stand alone program.
– Is not zero risk.
– HACCP is a work in progress.
• Strategy is to identify significant hazards, assess risk, and develop control.
Seven Principles of HACCP
1. Conduct a hazard analysis.
2. Determine the critical control points (CCPs) in the process.
3. Establish critical limits.
4. Establish monitoring procedures.
5. Establish corrective actions.
6. Establish record-keeping and documentation procedures.
7. Establish verification procedures.
Principle 1: Conduct a Hazard Analysis Hazard A biological, chemical, or physical agent that is reasonably likely to cause illness or injury in the absence of its control.
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Identify Hazards that warrant control
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Likelihood of occurrence = RISK
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Severity
Principle 2: Determine Critical Control Points (CCPs) CCP A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
• • •
Not all steps are CCPs May be multiple CCPs to address a single food safety hazard Last step(s) in a food preparation process which will control the food safety hazard
Principle 3: Establish Critical Limits Critical Limit A maximum and/or minimum value to which a biological, chemical, or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable level the occurrence of a food safety hazard.
• • •
Boundaries that define safety How you know when the CCP is under control = Measurable/quantifiable Can be found in the Food Code ex. Cooking hamburgers CL = 155 °F for 15 seconds
Principle 4: Establish Monitoring Procedures Monitoring
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A planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for use in future verification procedures.
Someone needs to keep track of the CCPs
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Who is responsible?
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How do they do it?
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How often do they do it?
Principle 5: Establish Corrective Actions Corrective Actions Procedures followed when a deviation occurs.
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What to do when things go wrong Keeping unsafe food from the consumer
Principle 6: Establish Verification Procedures Verification Activities, other than monitoring, that determine the validity of the HACCP plan and that the system is operating according to the plan.
• • • •
Making sure the whole system is in place and working Periodically checking, reviewing, calibrating, etc… Seeing if the HACCP system needs to be changed.
Includes VALIDATION of the HACCP plan.
Principle 7: Establish Record-keeping and Documentation Procedures
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Provide documentation that the critical limits at each CCP were met or that the appropriate corrective actions were taken when not met
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Provide documentation that the actions performed were verified and were consistent with the HACCP
Retail HACCP
Draft Retail HACCP Guide “...intended to assist industry’s voluntary implementation of HACCP principles.”
www.cfsan.fda.gov/~ear/retail.html
Food Service Industry Vs. Processing Industries?
• • •
Food Service not defined by specific commodities.
Many different ways of making the same menu item, e.g. using precooked chicken Vs. raw chicken in a chicken salad recipe.
Diversity among food service facility types, design and construction.
Defining Food Service HACCP
Application of HACCP Principles
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Active Managerial Control of Risk Factors Flexible Process-specific
Building Your Food Safety Management System Group menu items into 1 of 3 prep processes
Food Service HACCP
Considerations with ALL Processes:
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No bare hand contact with RTE food
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(or approved, alternate procedure) Proper Handwashing Datemarking Restriction or exclusion of ill employees
Food Service HACCP
Considerations with ALL Processes:
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Separation of raw animal foods with RTE foods to prevent cross-contamination Prevention of cross-contamination of RTE food or clean and sanitized food contact surfaces with soiled cutting boards, utensils, aprons, etc.
Food Service HACCP
Process #1: Preparation of RTE Food with No Cook Step Receive Store Prepare Hold Serve Examples: Tuna Salad, Sandwiches, Green Salads, Chicken Salad
Food Service HACCP
• • •
Considerations with Process 1 There is no cook step.
Focus on:
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cold holding or time alone
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food source (esp. shellfish and fish)
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receiving temps (esp. finfish)
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freezing to destroy parasites Be flexible Not every flow will be “textbook”
Food Service HACCP
Process #2: Preparation for Same Day Service Receive Store Prepare Cook Hold Serve Examples: Fried Shrimp, Macaroni & Cheese, Mashed Potatoes
Food Service HACCP
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Considerations with Process 2 Food will pass through the danger zone only once.
Focus on:
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Cooking
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Hot holding or using time alone
Food Service HACCP
Process #3: Complex Food Preparation Receive Store Prepare Cook Cool Reheat Hot Hold Serve Examples: Beef Stew, Soups, Gravy, Chili
Food Service HACCP
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Considerations with Process 3 Pass through the danger zone more than once.
Focus on:
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Cooking
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Cooling
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Hot and cold holding or using time alone
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Reheating
Danger Zone Diagram
Times through the Danger Zone 140 o F 1 2 3 41 o F COOK COOL Same Day Service REHEAT Complex Food Prep
Procedural Step 1 Develop Prerequisite Programs
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Procedures that address basic operational and sanitation conditions in an establishment Examples:
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Vendor certification programs
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Training programs Recipe/Process instructions Standard Operating Procedures (SOPs)
Procedural Step # 2
Group your Menu Items/Products •Process #1 – Food preparation with no cook step •Process #2 – Food preparation for same day service •Process #3 Complex Food preparation
Procedural Step # 3
Conduct a Hazard Analysis
3 Steps to Conducting a Hazard Analysis . . .
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Identify Hazards of Significance
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Assess the Risk and Severity of the Hazards
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Determine the Control Measures that May be Taken to Ensure that the Hazards are Controlled
Identifying Hazards of Significance
Consider . . .
• • •
Ingredients, processing, distribution and intended purpose Current research and epidemiology Foods within the same food prep process will have similar hazards
Assessing Risk and Severity R I S K Norwalk-like virus SEVERITY C. botulinum
General Categories of Hazards
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Biological
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Bacterial, viral, parasitic contamination
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Bacterial growth
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Bacterial toxin production Bacterial, parasitic, or viral cross-contamination
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Chemical
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Contamination
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Scombroid toxin
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Ciguatera
• Physical − Glass −Metal −Rocks −Plastic
Procedural Step # 4
Implementing control measures and Establishing critical limits
Determining Control Measures
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Actions or activities that can be used to prevent, eliminate, or reduce a hazard Examples: cooking, implementing an employee health policy, proper handwashing, preventing cross contamination
Determining critical limits
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Are usually established by a regulatory standard (Food Code) Measurable and quantifiable Can be tailored to a particular operation
Examples
PRODUCT: CCP: RAW HAMBURGER PATTY COOKING (WELL) CL:
155ºF for 15 seconds
PRODUCT: CCP: REFRIED BEANS REHEATING CL:
165ºF within 2 hours
PRODUCT: CCP: BEEF CHILI COOLING CL:
6 hours from 140ºF to 41ºF and 140ºF to 70ºF within the first 2 hours
Procedural Step # 5
Establishing Monitoring Procedures
Definition of monitoring
The act of observing and making measurements to help determine if critical limits are being met and maintained
Examples of Monitoring
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Visual observations Temperature Time pH Water activity
Consider the following . . .
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What you will monitor How you will monitor When and how often you will monitor
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Who will be responsible for monitoring
Who monitors
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Directly associated with the operation Trained and knowledgeable Accessible to monitoring activity Responsible
Procedural Step # 6
Develop Corrective Actions
Purpose of Corrective Actions
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To correct cause of deviation To determine proper disposition of affected food
Deciding on Corrective Actions
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What measures do you expect employees to take to correct the problem?
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Do your employees understand the corrective action?
Can the corrective action be easily implemented?
Procedural Step 7
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Conduct On-Going Verification
– Verification is and oversight auditing process to ensure that the HACCP plan and SSOPs continue to be adequate and consistently followed.
On-going Verification activities include
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Observing the person doing the monitoring – is it being done as planned Reviewing monitoring Records Checking Corrective Action Reports Periodically reviewing the total plan Test product in process Review equipment calibration records
Procedural Step 8
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Record Keeping – A record keeping system can be simple and needs to be designed to meet the needs of your operation
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Accurate record keeping is an essential part of a successful HACCP Program
Procedural Step 8
5 Types of Records 1. Records related to prerequisite programs 2. Monitoring records
3. Corrective actions records 4. On-going verification and periodic validation records 5. Calibration records
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Procedural Step 8
Take into consideration…
Simple records are easier to maintain How are records maintained Who is responsible for record maintenance How long will the records be kept