Transcript Vacuum Packaging Module
Vacuum Packaging
Food Safety Principles
Retail Meat & Poultry Processing Training Modules
Produced under a Cooperative Agreement from the United States Department of Agriculture Food Safety and Inspection Service (FSIS)
Developed by:
Minnesota Department of Agriculture, Dairy and Food Inspection Division Hennepin County Environmental Health Minnesota Department of Health University of Minnesota Extension Service September 2004
Pretest
Topics
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Reduce oxygen packaging methods
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Advantages/risks Primary controls temperature, types of food packaged, shelf life and sanitation
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Back flushing Packaging Labeling HACCP Plan requirements Training
Learning Objectives
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6.
Understand the advantages and risks of vacuum packaged foods.
Know what particular group of bacteria presents the greatest risk in vacuum-packaged foods and why.
Understand how the food safety hazards are controlled.
Explain the reason retailers use a shelf life for vacuum-packaged foods of no longer than 14 days while USDA manufacturers often use 30-45 days.
Define back flushing . Give an example when ‘back flushing’ would be used.
Know the labeling requirements for retail vacuum packaged foods.
What is Reduced Oxygen Packaging?
Food in a package with less oxygen than normal
Reduced Oxygen Packaging (ROP)
Vacuum packaging Modified Atmosphere Packaging Controlled Atmosphere Packaging Others: Cook Chill or
Sous Vide
Advantages of ROP
• Extend shelf life • Slows the growth of spoilage organisms • Prevent color changes • Prevent shrinkage and moisture loss
What’s the Hazard?
Biological Hazards
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Pathogenic bacteria
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Bacteria that grow without oxygen
Clostridium
Listeria
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Spoilage microbes will not grow Less competition for other bacteria
Bacteria of Concern
Bacteria that grow in an environment without oxygen
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Clostridium botulinum
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Produces a toxin that is not eliminated by heat
Listeria monocytogenes
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Grows at temperatures down to 32 °F A concern in ready-to-eat foods as a result of cross contamination
Primary Controls
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Temperature
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Types of Food Package
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Shelf Life
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Sanitation
Temperature
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Keep cold at 41 °F or less
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Minimize time out of refrigeration during processing
Types of Food Packaged
Retail Food Code regulations limit the types of food that can be vacuum packaged to:
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Raw meat or poultry (beef, pork, chicken) Hard cheese (colby, cheddar, swiss) Cured meats (sausage, ham, smoked turkey) Food with a low pH (below 4.6) or low water activity level (below .91) Fish ONLY if frozen before, during and after packaging
Shelf Life
• Limit the shelf life to 14 days from day of packaging • Increase in shelf life increases the risk of
Listeria
growth
Developing SSOP’s Written Procedures
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Detailed procedures for cleaning and sanitizing.
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A checklist of equipment to be cleaned and the frequency to be cleaned.
Steps for the tear-down and re-assembly of equipment.
Procedures and schedule for cleaning non food contact surfaces and facilities.
Instructions for use of sanitation chemicals.
More SSOPs
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Employee practices Steps for preparing and storing foods
»
Monitoring temperatures
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Preventing cross contamination
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Pest Control
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Facility and Grounds Maintenance
Flow Diagram
Storage of Food and Packaging Materials Assembly and Vacuum Packaging of Foods Weigh and Label Finished Product Storage Retail Display or Cooler Storage
Storage: Foods & Packaging Materials
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Keep potentially hazardous food at 41 °F or less.
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Store food to prevent cross contamination .
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Store packaging materials in a sanitary manner.
Assembly & Packaging
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Limit time out of refrigeration.
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Re-chill to 41 °F or less.
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At retail, only certain foods can be vacuum packaged.
Packaging
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When packaging ready-to-eat foods, limit bare hand contact.
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Utensils, tissues or gloves must be used.
Packaging
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Use the vacuum packaging machine according to manufacturers instructions.
If using a gas displacement, be sure equipment is used safely and effectively.
Packaging
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Designated area for ROP Separate raw from ready-to-eat
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Physical barrier Timing of operations Check the packages for:
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Tight seal Tight vacuum
Packaging Materials
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Plastic films must be approved for ROP food packaging
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Different types of films can provide barriers to water, oxygen, flavors, odors
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Other properties: toughness, brittleness, impact resistance
Labeling
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Basic labeling requirements Statement to ‘Keep Refrigerated or Frozen’
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Instructions to discard if not used within 14 days of packaging
Finished Product Storage
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ROP packaged food must be stored at 41 °F or less
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Monitor and record the temperature in all storage units
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Check products daily for faulty seals, puffy packages
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Outdated products must be discarded
HACCP
Hazard Analysis Critical Control Points
1. Hazard Analysis 2. Critical Control Points 3. Critical Limits 4. Monitoring 5. Corrective Actions 6. Recordkeeping 7. Verification
HACCP Activity
1. Critical Control Point 2. Monitoring Frequency 3. Corrective Action 4. Records 5. Verification of instruments 6. SSOPs A) Calibrate thermometer B) Written procedures for how to clean C) Temperature logs D) Refrigerated storage of 41
F or less E) Check case temperature twice daily F) Discard product G) Reheat to 165
F
HACCP
Key Points for a ROP HACCP plan :
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Cold hold at 41 °F or less
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Frequency of monitoring temps
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ROP food that has been temperature abused must be discarded
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Maintain records – temperature logs
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Calibrate thermometers
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Written SSOPs
Training
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Develop a Training Program for employees responsible for the ROP operation.
Items to be included:
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Concepts required for a safe operation Equipment and facilities Direct hand contact w/ RTE food Contents of the HACCP plan
Summary
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Hazards with ROP products
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Clostridium botulinum, Listeria monocytogenes
Controls
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Temperature of 41 °F or less Limiting the types of food packaged Shelf life maximum of 14 days Sanitation – cleaning and hand contact HACCP and SSOPs
Wrap-Up
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Do you have any questions?
What information was new?
How will you apply what you learned today?
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Posttest