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APPLYING FOOD SCIENCE TO INNOVATE NEW PROCESSES IN RETAIL FOOD OPERATIONS

PRESENTED ATIFT ANNUAL MEETING AND FOOD EXPO

LAS VEGAS, NEVADA 2004

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 5984osnyder@hi-tm.com http://www.hi-tm.com

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NEW PROCESS INNOVATION• The chef / cook / home food preparer is the one who innovates new

processes and validates safety by serving the food. • Many kitchens (e.g., home, small retail food, food shelves, etc.) are not

inspected. There will be fewer inspections in the future because of shrinking dollars. Regulatory inspection is not prevention. Inspectors are not trained to do process approval.

• The FDA has no responsibility, and does no research, for development of new retail process and process performance standards or for validating / verifying new processes as safe.

• Local public health sanitarians with no prescribed food process technical education in HACCP are designated by the code to approve variances. The variance only applies to the one retail food operation / one approving jurisdiction. This will not work for new process approval. At the same time, local inspectors can establish any process standard as long as it is more stringent than their agency's standard, but they have no qualifications.

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NEW PROCESS INNOVATIONUSING FEDERAL PERFORMANCE STANDARDS

Where can cooks get new process performance standards when the they are not available from the FDA and inspectors?

They can get them from other agencies. The FDA Food Code (2001, preface iv) says that anyone can use any approved federal performance standard, as from the USDA or FDA Fisheries HACCP, that achieves the same end process standard. This fact will be demonstrated by the unit with a HACCP plan validated by a process authority.

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FOOD PREPARERS DO RISK MANAGEMENTAND REDUCE THE HAZARD

TO AN ACCEPTABLE LEVEL OF PROTECTION (ALOP)

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RETAIL PROCESS HACCP / RISK MANAGEMENT (NACMCF)

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HACCP ALLOWS OPERATORS TO DO ANY PROCESS THAT CAN PRODUCE SAFE FOOD

• Produce chilled and frozen entrees and meals with operator-selected shelf life; use CO2 and MAP to extend shelf life.

• Produce sterilized soups and sauces.• Produce acidified, shelf-stable sauces and dressings.• Produce shelf-stable, low-water-activity food such as jams, jellies, jerky.• Produce all kinds of packaged pastries and cookies with extended shelf life.• Produce fermented foods such as sausage, cheese, yogurt, sauerkraut, kimchee,

beer / wine / vinegar.• Thaw on the counter.• Precool hot food at room temperature before refrigerating.• Cool from 120 to 40ºF in 14.4 hours.• Slow cook at 130ºF, 90% Rh.• Hold food at any temperature from 30 to 130ºF, for up to 10 multiplications of

pathogens.• Hold ready-to-eat food at 130ºF or at 40ºF with no time limit.• Display and sell food at room temperature, such as sushi and Korean rice cakes,

<10 generations of pathogens (~1 day).• Produce food for home meal replacement; delivered in town or anywhere in the U.S.

by UPS, FEDEX, etc.

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COOK CAPABILITY CERTIFICATIONthat they have scientifically correct

food science control information

Ask the cook:• What are you preparing?• What are the hazards in the prerequisite and food

processes?• The significant B,C,P hazards are _____________.• My validated controls are ______________.• I monitor that I have achieved the control standard by

________________.

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CHEF – HOW DO YOU KNOW YOU ARE SERVING SAFE FOOD?

• I defined the system.• I wrote the food safety checklist for the system

(a simple policies, procedures, and standardsmanual).

- Menu- Processes (prerequisite and food)- Hazards in ingredients and significant levels- Controls for the hazard

• I trained my employees to control the hazardsin the menu items that they produce.

• I inspected for effective control by employees.• I have a continuous quality improvement program.

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PROCESS SAFETY VALIDATION BY THE CHEF

• How does the chef assure that a process design will produce a safe product and that the hazards are at an acceptable level of protection?

• The chef designs using HACCP, a rational, scientific process to develop processes that control the hazards from the farm, environment, or food worker.

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THE RETAIL FOOD SYSTEM

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5. EquipmentLubricantsWeld material that breaks looseSlicer blades that chipToxic metal surfacesLobes of pumps that breakNuts, bolts, o-rings

6. Supplies / IngredientsPackaging materialsChemical suppliesFlavors and colorsChemical additives

For all commodities, determine if the supplier makes the food safe (prevents / eliminates / reduces biological, chemical, and physical hazards to a tolerable level) or if the cooks do.

3. Environment(outside the facility)Water, safe sourcePower loss, frozen and

refrigerated food controlStorm damage control (flood,

ice, earthquakes)Insects, rodents, birds

4. FacilityLights, broken glass,

dirt overheadDrains, floorsPest control chemicals / trapsRefrigerator / freezer

temperaturesBoiler water treatment

chemicals

PREREQUISITE PROCESS HAZARDS1. ManagementEnforcement of food safetyRecall proceduresOutbreak proceduresBio-security proceduresHACCP Team operation

2. PersonnelFeces on fingertipsHair, nails, jewelryCuts on hands,

blowing noseCoughing on foodClothes, pant legsLoose physical objects

(fall in food)

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FOOD PROCESS HAZARDS

Chemical hazards- Allergy-causing ingredients- Food toxic substances- Chemical additives (sulfite, nitrate)

Biological hazards- Vegetative pathogens in raw food

- Spores in pasteurized food

Physical hazards to be removed or prevented from getting into food when the food is opened (identify foods)- Metal pieces / chips from can openers

- Glass / plastic- Rocks / dirt / twigs- Bone chips / pieces- Plastic wrap- Metal blades (e.g., box cutters)

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SAFE PROCESS DESIGN

1. Hazard inventory (proven hazard, 95% critical limit).- Environment - Natural toxins

(water) - Chemicals / additives / allergens- Human (fecal) - Physical - Equipment - Microbiological (physical, microbiological)

2. Process innovation research to reliably reduce the hazard to a safe limit, if necessary.Write up the process and get peer review.

3. Safe new process. Tolerable level of pathogenic substances. They meet Food Safety Objectives.

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HACCP PROCESS CONTROL STUDY(Publish in peer-reviewed publication)

• Introduction- Describe the process. Do a flow chart

and ingredients- Describe the hazard(s)- Describe the need for a control- Describe a proposed control to be studied

• Methods• Results• Discussion• Conclusion: Did or did not the study

validate the control?

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PROCESSES CAN BE GROUPED BY FOOD SAFETY HAZARD (USDA)

• Slaughter• Raw product (with center contamination) (hamburger, green

onions)• Raw solid product (no center contamination) (beef steak,

potatoes)• Thermal, commercially sterile (canned)• Not heat treated, shelf stable (pH aw, fermentation)• Heat treated, shelf stable (pasteurization + additive)• Fully cooked, not shelf stable (retail)• With secondary inhibitors, not shelf stable (small levels of

inhibitors)

Processes can be grouped when the food safety hazards, critical control points, critical limits, and control procedures are essentially the same, or features unique to a specific product are clearly delineated.

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GENERAL COOK-AND-SERVE HACCPSupplier intervention or cook makes safePurchase

Receive, Store

Pre-prep

Prep

Transport, Hold,Serve

Cool

Not significant; <50ºF spoilage

Not significant; <50ºF spoilage

CCP: 5D (150ºF, 1 minute); 2D wash fruits and vegetables; 5D wash food contact surface

CCP: <3 log increase if between 40 and 130ºF and food is not saved; if saved, hold ≤40ºF / >130ºF for a <1 log increase

CCP: <1 log increase

CCP: <3 log increase before consumption; reheating not a safety control; customer warning label

Customer abuse

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CHICKEN CACCIATORE HACCP PROCEDURES AND RECORD

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HOW TO WRITE A HACCP RECIPE STEPA recipe step, if written in the following standardized form, can be analyzed by a computer for significant biological, chemical, and physical hazards and the adequacy of the controls.

Process step

time, hr. / min.

End food ctr.

temp., ºF

Temp. on /

around food

CoverYes / No

Container size

HxWxL (in.)

Thickest food

dimension (in.)

Start food ctr.

temp., ºF

FoodProcess step #

Example: Cool stew, 2 inches deep (2 ½" x 12" x 2"), covered, in 35ºF refrigerator, from 130 to 40ºF in 6 hours.

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CHICKEN CACCIATORE HACCP RECIPE FLOW

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CHICKEN CACCIATORE HACCP PLAN

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CHICKEN CACCIATORE HACCP PLAN (CONT'D)

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HOW OPERATORS CONTROL SO THAT THEY DO NOT NEED REGULATORY INSPECTION

Kitchen HACCP Team

• The chef establishes a HACCP team with the kitchen staff.

• They develop a food safety checklist as a simple alternative to the policies, procedures, and standards manual.

• All kitchen personnel are trained by the HACCP team to perform to the checklist standards.

• The HACCP team meets once a month to review deviations and make improvements.

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A PLAN FOR CHEF-BASED, SAFE, NEW PROCESS INNOVATION

• Owner must empower the chef, who takes responsibility.

• Must have correct science. Foodservice Division, with the advice of all other IFT Divisions, to develop process standards.

• IFT scientific curriculum for chefs.

• Chefs teach home food preparers in their communities.

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RETAIL PROCESS PERFORMANCE STANDARDS

• Physical hazard: <1/16 inch.• Chemical hazard: At tolerable levels.• Remove fecal pathogens from fingertips: 6D reduction.• Wash food pathogens from hands: 3D reduction.• Wash food pathogens from food contact surfaces: 5D reduction.• Supplier safe with HACCP intervention process, or cook makes safe.• Wash fruits and vegetables for a 2D reduction or blanch for a 5D reduction.• Pasteurize meat, poultry, fish for a 5D reduction of Salmonella.• Sterilize food for a 12D reduction of Clostridium botulinum.• Cool 120 to 55ºF, 6 hours (to 40ºF, 14.4 hours); <1 log increase of

Clostridium perfringens.• Acidify: Salmonella control <4.1 pH

C. botulinum control <4.6 pH• Aw: <0.86 aw Staphylococcus aureus control

<0.92 aw Bacillus cereus control• Cold hold <40ºF, no spore outgrowth; no time limit. If held 40 to 130ºF,

or given to consumer for take-out, <3 log increase.

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EMPLOYEE FOOD SAFETY REMINDERFood pasteurization; ≥5DRoast beef 130°F 86 minutesSolid chops 145°F 3 minutesGround beef 155°F 15 secondsPoultry 165°F 15 seconds

Hot hold 130°F OR 4 hours, 90 to 115ºF

Cool ≤ 2 inches, <1 gallon, 120 to 40ºF, 14.4 hours

Cold hold 40°F, unlimited time

Make salads from cold ingredients, <50°F

Do not add fresh to old (FIFO)

Allergens

Personal hygieneDouble wash after toilet; 6DSingle wash after raw meat, poultry; 3DGloves: Not required

Clean food contact surfacesScrap-wash-rinse-sanitize-air dry; 5D

Receive: 41°F, no damageRaw on bottom; RTE on top

Control chemical and physical hazards

Double wash fruits and vegetables; 2D

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SUMMARY• The chef / cook innovates new processes.• The chef / cook must validate process performance

standards, because the FDA is not required to and does not.

• The chef / cook must control the safety of the process.

• The IFT is the best source of experts to provide retail process performance standards and HACCP information.

For a copy of this presentation, go to:http://www.hi-tm.com/Documents2004/apply-food-sci.pdf