All information contained in this document is proprietary to Abu Dhabi Airports Company (ADAC) and shall not be duplicated in any manner or released in part or full to any unauthorized persons. However, the contents of this document are not confidential and shall be accessible to all ADAC employees and its subsidiaries.

Food Operations, Health and Safety Food Operations - Hospitality

Business Process Area / Functional Area:

Hospitality (HP)

04 Food Operations (FO)

Manual Owner: Executive Chef

Manual Ref. No.: MA/HP/04/FO/01

Implementation Date: DD/MM/YYYY

Approved By: Name/Title/Department

Approval Date: DD/MM/YYYY

Version No.: V1.0

Version Date: 08/05/2012

Approver’s Signature:

(for non-electronic copies) (for non-electronic copies)

Information Classification Official Use Official Use Official Use

A manual consolidates all information and documentation supporting the management and implementation of a function in the organization (collection of information and documentation relating to a specific work area, field, topic, project, system). The content of the manual template may be changed as appropriate depending on the

subject and purpose of the manual. A manual can be used for both best practice and standard.

Template Title: Manual Template Template Ref. No.: TEM/02/MAN Version No.: V2.0 Version Date: 14/02/2012

Manual Title: Food Operations, Health and Safety

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Table of Contents

1. Title ................................................................................................................................ 3

2. Purpose ......................................................................................................................... 3

3. Scope ............................................................................................................................. 3 4. Definitions and Abbreviations ........................................................................................ 3

5. Food Operations Risk Management and Control ........................................................ 10

6. Food Safety ................................................................................................................. 12

7. Food Operations Safety ............................................................................................... 15

8. Procedures .................................................................................................................. 15

9. Framework (optional) ................................................................................................... 15 10. Governance (optional) ................................................................................................. 16

11. Budget (optional) ......................................................................................................... 17

12. Responsibilities of Stakeholders .................................................................................. 17

13. Potential Risks ............................................................................................................. 17

14. Equipment and Material Required (optional) ............................................................... 17

15. Contact List (optional) .................................................................................................. 17 16. Lessons learnt (optional) ............................................................................................. 17

17. Supporting Documentation and Tools ......................................................................... 18

18. Filing and Distribution .................................................................................................. 18

19. Change Log ................................................................................................................. 18

20. Appendix ...................................................................................................................... 18

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1. Title

Food Operations, Health and Safety

2. Purpose

3. Scope

4. Definitions and Abbreviations

Definitions Description

Food preservation

Food preservation is the process of treating and handling food to stop or slow down spoilage (loss of quality, edibility or nutritional value) and thus allow for longer storage.

Preservation usually involves preventing the growth of bacteria, yeasts, fungi, and other micro-organisms (although some methods work by introducing benign bacteria, or fungi to the food), as well as retarding the oxidation of fats which cause rancidity. Food preservation can also include processes which inhibit visual deterioration (when something becomes less closer to the original) that can occur during food preparation; such as the enzymatic browning reaction in apples after they are cut.

Many processes designed to preserve food will involve a number of food preservation methods. Preserving fruit, by turning it into jam, for example, involves boiling (to reduce the fruit’s moisture content and to kill bacteria, yeasts, etc.), sugaring (to prevent their re-growth) and sealing within an airtight jar (to prevent recontamination). There are many traditional methods of preserving food that limit the energy inputs and reduce carbon footprint.

Maintaining or creating nutritional value, texture and flavour is an important aspect of food preservation, although, historically, some methods drastically altered the character of the food being preserved. In many cases these changes have now come to be seen as desirable qualities – cheese, yoghurt and pickled onions being common examples.

Preservation processes

Heating to kill or denature micro-organisms (e.g., boiling)

Ozonation (e.g., use of ozone or ozonated water to kill undesired microbes)

Toxic inhibition (e.g., smoking, use of carbon dioxide, vinegar, alcohol etc.)

Dehydration (drying)

Osmotic inhibition (e.g., use of syrups)

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Low temperature inactivation (e.g., freezing)

Combinations of these methods

Drying

Drying is one of the most ancient food preservation techniques, which reduces water activity sufficiently to prevent or delay bacterial growth.

Refrigeration

Refrigeration preserves food by slowing down the growth and reproduction of micro-organisms and the action of enzymes which cause food to rot.

Refrigeration allows foods such as fresh fruit, salads and dairy products to be stored safely for longer periods, particularly during warm weather.

Freezing

Freezing is also one of the most commonly used processes commercially and domestically for preserving a very wide range of food including prepared food stuffs which would not have required freezing in their unprepared state.

Vacuum packing

Vacuum-packing stores food in a vacuum environment, usually in an air-tight bag or bottle.

The vacuum environment strips bacteria of oxygen needed for survival, slowing spoiling.

Vacuum-packing is commonly used for storing nuts to reduce loss of flavor from oxidation.

Salt

Salting or curing draws moisture from the meat through a process of osmosis. Meat is cured with salt or sugar, or a combination of the two.

Nitrates and nitrites are also often used to cure meat and contribute the characteristic pink color, as well as inhibition of Clostridium botulinum.

Sugar

Sugar is used to preserve fruits, either in syrup with fruit such as apples, pears, peaches, apricots, plums or in crystallized form where the preserved material is cooked in sugar to the point of crystallisation and the resultant product is then stored dry.

This method is used for the skins of citrus fruit (candied peel), angelica and ginger. A modification of this process produces glacé fruit such as glacé cherries where the fruit is preserved in sugar but is then extracted from the syrup and sold, the preservation being maintained by the sugar content of the fruit and the superficial coating of syrup.

The use of sugar is often combined with alcohol for preservation of luxury products such as fruit in brandy or other spirits. These should not be confused with fruit flavored spirits such as cherry brandy or Sloe gin.

Another method for preservation consists of using sugar at high and low temperature.

Smoking

Smoking is used to lengthen the shelf life of perishable food items. This effect is achieved by exposing the food to smoke from burning plant materials such as wood. Most commonly subjected to this method of food preservation are meats and fish that have undergone curing.

Fruits and vegetables like paprika, cheeses, spices, and ingredients for making drinks such as malt and tea leaves are also smoked, but mainly for cooking or

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flavoring them.

It is one of the oldest food preservation methods, which probably arose after the development of cooking with fire.

Pickling

Pickling is a method of preserving food in an edible anti-microbial liquid. Pickling can be broadly categorized as chemical pickling for example, In chemical pickling, the food is placed in an edible liquid that inhibits or kills bacteria and other micro-organisms.

Typical pickling agents include brine (high in salt), vinegar, alcohol, and vegetable oil, especially olive oil but also many other oils.

Many chemical pickling processes also involve heating or boiling so that the food being preserved becomes saturated with the pickling agent.

Common chemically pickled foods include cucumbers, peppers, corned beef, herring, and eggs, as well mixed vegetables such as piccalilli.

In fermentation pickling, the food itself produces the preservation agent, typically by a process that produces lactic acid.

Fermented pickles include sauerkraut, nukazuke, kimchi, surströmming, and curtido. Some pickled cucumbers are also fermented.

Canning and bottling

Canning involves cooking food, sealing it in sterile cans or jars, and boiling the containers to kill or weaken any remaining bacteria as a form of sterilization. It was invented by Nicolas Appert.

Foods have varying degrees of natural protection against spoilage and may require that the final step occur in a pressure cooker. High-acid fruits like strawberries require no preservatives to can and only a short boiling cycle, whereas marginal fruits such as tomatoes require longer boiling and addition of other acidic elements.

Low acid foods, such as vegetables and meats require pressure canning. Food preserved by canning or bottling is at immediate risk of spoilage once the can or bottle has been opened.

Jellying Aspic

Food may be preserved by cooking in a material that solidifies to form a gel. Such materials include gelatine, agar, maize flour and arrowroot flour.

Some foods naturally form a protein gel when cooked.

Modified atmosphere

Modifying atmosphere is a way to preserve food by operating on the atmosphere around it. Salad crops which are notoriously difficult to preserve are now being packaged in sealed bags with an atmosphere modified to reduce the oxygen (O2) concentration and increase the carbon dioxide (CO2) concentration

Modifying atmosphere is possible by using a block of dry ice, Nitrogen gas (N2) at concentrations of 98%, air-tight storage.

Principal hurdles used for food preservation

Parameter Symbol Application

High temperature F Heating

Low temperature T Chilling, freezing

Reduced water activity aw Drying, curing, conserving

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Increased acidity pH Acid addition or formation

Reduced redox potential Eh Removal of oxygen or addition of ascorbate

Hazard analysis and critical control points

Hazard analysis and critical control points, or HACCP is international standard followed in food operations.

HACCP is a systematic preventive approach to food safety and pharmaceutical safety that identifies physical, chemical, and biological hazards in production processes that can cause the finished product be unsafe, and designs measurements to reduce these risks to a safe level.

In this manner, HACCP is referred as the prevention of hazards rather than finished product inspection.

The HACCP system can be used at all stages of a food chain, from food production and preparation processes including packaging, distribution, etc.

HACCP seven principles

Principle 1: Conduct a hazard analysis. – Plans determine the food safety hazards and identify the preventive measures the plan can apply to control these hazards. A food safety hazard is any biological, chemical, or physical property that may cause a food to be unsafe for human consumption.

Principle 2: Identify critical control points. – A critical control point (CCP) is a point, step, or procedure in a food manufacturing process at which control can be applied and, as a result, a food safety hazard can be prevented, eliminated, or reduced to an acceptable level.

Principle 3: Establish critical limits for each critical control point. – A critical limit is the maximum or minimum value to which a physical, biological, or chemical hazard must be controlled at a critical control point to prevent, eliminate, or reduce to an acceptable level.

Principle 4: Establish critical control point monitoring requirements. – Monitoring activities are necessary to ensure that the process is under control at each critical control point.

Principle 5: Establish corrective actions. – These are actions to be taken when monitoring indicates a deviation from an established critical limit. The final rule requires a plant's HACCP plan to identify the corrective actions to be taken if a critical limit is not met. Corrective actions are intended to ensure that no product injurious to health or otherwise adulterated as a result of the deviation enters commerce.

Principle 6: Establish procedures for ensuring the HACCP system is working as intended. – Validation ensures that the plants do what they were designed to do; that is, they are successful in ensuring the production of a safe product. Plants will be required to validate their own HACCP plans. FSIS will not approve HACCP plans in advance, but will review them for conformance with the final rule.

Verification ensures the HACCP plan is adequate, that is, working as intended. Verification procedures may include such activities as review of HACCP plans, CCP records, critical limits and microbial sampling and analysis. FSIS is requiring that the HACCP plan include verification tasks to be performed by plant personnel. Verification tasks would also be performed by FSIS inspectors. Both FSIS and industry will undertake microbial testing as one of several verification activities.

Verification also includes 'validation' – the process of finding evidence for the accuracy of the HACCP system (e.g. scientific evidence for critical limitations).

Principle 7: Establish record keeping procedures. – The HACCP regulation requires that all plants maintain certain documents, including its hazard analysis and written HACCP plan, and records documenting the monitoring of critical control points, critical

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limits, verification activities, and the handling of processing deviations.

HACCP Standards

The seven HACCP principles are included in the international standard ISO 22000 FSMS 2005. This standard is a complete food safety and quality management system incorporating the elements of prerequisite programs (GMP & SSOP), HACCP and the quality management system, which together form an organization’s Total Quality Management system.

HACCP training

HACCP management system trainings are only offered by several commercial companies.

HACCP application

Applied range

It can apply to several food categories; sea food, bulk milk production line, Bulk Cream and Butter Production Line, animal meat industry, Organic Chemical Contaminants in Food, Corn Curl Manufacturing Plant, etc. As example:

Fish and fishery products

Fresh-cut produce

Juice and nectar products

Food outlets

Meat and poultry products

School food and services

HACCP Implementation

It involves monitoring, verifying and validating of the daily work that is compliant with regulatory requirements in all stages all the time.

HACCP versus ISO 22000

ISO 22000 is the new standard bound to replace HACCP on issues related to food safety..

ISO 22000 will not replace HACCP. The requirements for HACCP are set with global agreement by the United Nations Codex Alimentarius Commission - and these are the basis for international trade and national legislation around the world.

HACCP is a system - ISO 22000 is a standard. ISO 22000 can be used to measure the success of a company's implementation of HACCP, as well as pre-requsites to HACCP and quality systems. There are other standards that can also be used - ISO 22000 is not the only one.

Risk analysis

Risk analysis is defined for the purposes of the Codex Alimentarius Commission as "A process consisting of three components: risk management, risk assessment, and risk communication."

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The diagram above illustrates the relationship between the three components of risk analysis

Risk management

Risk management is defined for the purposes of the Codex Alimentarius Commission as "The process, distinct from risk assessment, of weighing policy alternatives, in consultation with all interested parties, considering risk assessment and other factors relevant for the health protection of consumers and for the promotion of fair trade practices, and, if needed, selecting appropriate prevention and control options."

Risk assessment

Risk assessment is defined for the purposes of the Codex Alimentarius Commission as "A scientifically based process consisting of the following steps: (i) hazard identification, (ii) hazard characterization, (iii) exposure assessment, and (iv) risk characterization."

Hazard identification is "The identification of biological, chemical, and physical agents capable of causing adverse health effects and which may be present in a particular food or group of foods."

Hazard characterization is "The qualitative and/or quantitative evaluation of the nature of the adverse health effects associated with biological, chemical and physical agents which may be present in food. For chemical agents, a dose-response assessment should be performed. For biological or physical agents, a dose-response assessment should be performed if the data are obtainable."

Exposure assessment is "The qualitative and/or quantitative evaluation of the likely intake of biological, chemical, and physical agents via food as well as exposures from other sources if relevant."

Risk characterization is "The qualitative and/or quantitative estimation, including attendant uncertainties, of the probability of occurrence and severity of known or potential adverse health effects in a given population based on hazard identification, hazard characterization and exposure assessment."

Risk communication

Risk communication is defined for the purposes of the Codex Alimentarius Commission as "The interactive exchange of information and opinions throughout the risk analysis process concerning hazards and risks, risk-related factors and risk perceptions, among risk assessors, risk managers, consumers, industry, the academic community and other interested parties, including the explanation of risk assessment findings and the basis of risk management decisions."

Codex Alimentarius Commission

The Codex Alimentarius Commission "...was created in 1963 by the Food Agriculture Organization (FAO) and the World Health Organization (WHO) to

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develop food standards, guidelines and related texts such as codes of practice under the Joint FAO/WHO Food Standards Program.

The main purposes of this Program are protecting health of the consumers and ensuring fair trade practices in the food trade, and promoting coordination of all food standards work undertaken by international governmental and non-governmental organizations."

Food quality Food quality is the quality characteristics of food that is acceptable to consumers.

This includes external factors as appearance (size, shape, color, gloss, and consistency), texture, and flavor.

Food Spoilage Spoilage is the process in which food deteriorates to the point in which it is not edible to humans or its quality of edibility becomes reduced. Various external forces are responsible for the spoilage of food.

Food that is capable of spoiling is referred to as perishable food.

Signs

Signs of food spoilage may include an appearance different from the food in its fresh form as:

Change in color,

Change in texture,

Unpleasant smell,

Undesirable taste.

(The item may become softer than normal. If mold occurs, it is often visible externally on the item).

Food Safety Food safety is a scientific discipline describing handling, preparation, and storage of food in ways that prevent food borne illness. This includes a number of routines that should be followed to avoid potentially severe health hazards.

The five key principles of food hygiene are:

1. Prevent contaminating food with pathogens spreading from people, pets, and pests.

2. Separate raw and cooked foods to prevent contaminating the cooked foods.

3. Cook foods for the appropriate length of time and at the appropriate temperature to kill pathogens.

4. Store food at the proper temperature.

5. Do use safe water and cooked materials.

Abbreviations Description

HACCP Hazard analysis and critical control points

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5. Food Operations Risk Management and Control

1. Food Operations Standards

Food Supply:

Defined standard list of food items with brand name and supplier

Food Stock:

Food items (dry and frozen) are stored based on pre-defined minimum/maximum stock levels

Expiry dates of stored items must not exceed 6 months by receiving from suppliers

Ordering:

Items are ordered based on menus

Orders are placed 24 hours in advance for fresh vegetables, fruits, frozen items and dry stored items

Orders are placed 36 hours in advance for fresh meat and poultry

Missing items must be notified immediately and have to be delivered on the same day.

Food operation:

“Zero” waste policy: all food supplied are utilized to a maximum level.

Menus will be adapted to ensure maximum level of food utilization is maintained.

Communication:

Reporting

Recording

Review and update

2. Monitoring

Risk assessment and quality control are performed on day-to-day basis with regular checks at each food operation step: from receiving to serving a product:

Quantitative checks

Qualitative checks:

Temperature

Visual

Odor

Period prior expiry

Production date

Risk analysis is based in a number of food operations criteria defined in the Food Operations SOP.

Checks conducted every:

Shift by Shift Leaders

Delivery by receivers

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Spot checks by Sous-Chef

3. Analysis

Identify repetitive errors or deviations to standards

Elimination of errors and deviation:

Change of supplier

Amend standards and operating procedures

Define improvement initiatives

Conduct sample analysis as needed to verify quality, health and safety are met

4. Corrective Actions

Missing items:

Call supplier for immediate delivery

Quality of food delivered not meeting the standard

Call supplier for immediate replacement

Breakdown of chiller

Immediate repair

Adapt the menu

Report wasted items and discard

5. Preventive Actions

Communication with supplier setting the standards

Temperature standards

Hygiene standard procedures

Food handling standards procedures (receiving, storage, cutting)

Implementation improvement initiatives

6. Record Keeping

To be in placed:

Risk Assessment Register

Incident Register

Menus record

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6. Food Safety

6.1 Time and Temperature Control

Time and temperature control plays a critical role in food safety.

To minimize the amount of time food spends in the danger zone, foods should be moved through the danger zone as lesser time as possible when reheating or cooling.

The danger zone is defined as 5°C - 63°C

Foods with higher potential risk in the danger zone:

Meat, Fish, poultry

Eggs, protein rich foods

Dairy products

Cut or peeled fresh produce

Cooked vegetables, beans, rice, pasta

Shellfish

Sauces such as gravy

Sprouts

Any foods containing the above, ex. Casseroles, salads, quiches.

6.2 Cooling Down

In order to ensure that foods are kept out of the danger zone, the following cooling down methods are used:

Staff using thermometers:

Chiller thermometers

Portable thermometers for checking the temperature when receiving and when food displayed in the buffets

Cooling down process:

Blaster chiller used cooling down cooked food from 100°C to 5°C in maximum time of 2 hours depending of the initial volume.

Temperature is monitored by the blaster chiller thermometer.

Cold food in the buffet must be kept at 5°C and maximum 2 hours displayed.

Food chilled at kept between 0°C and 5°C

Frozen food are kept between -18°C and -22°C

6.3 Heating Up

General:

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Cooking food until the core temperature is 75 °C or above will ensure that harmful bacteria are destroyed.

However, lower cooking temperatures are acceptable provided that the core temperature is maintained for a specified period of time as follows:

60 °C for a minimum of 45 minutes

65 °C for a minimum of 10 minutes

70 °C for a minimum of 2 minutes

Hot food in the buffet must be kept above or on minimum of 63°C and maximum 2 hours displayed

In Rational oven:

Prepared food: prepared food is cooked in the oven based on core temperature (minimum 65°C) on heat and steam for time period of minimum of 15 minutes depending of the product, quantity, gravy or non gravy

Raw food: raw food is cooked based on core temperature using oven thermometer depending on the product

Stovetop (hot range):

Different cooking method is used depending on the food style: boiling, steaming, frying, sauté, mijoté, sizzling, etc.

6.4 Food Labeling

As part of the food control and safety, all food items (incoming food as well as food handled in the kitchen) must be labeled with the following information:

Food item name

Production date

Expiry/best before date

Freezer Expiry date (if applicable)

For food items stored in the freezer and removed out of the freezer/box and stored in the chiller, a new label must be placed in the food item indicating the new expiry date as per the method of food handling as follows:

Food item name

Production date

Freezer Expiry date

Preparation before + date

For food items quickly defrosted and directly cooked and stored in the chiller, the new label must be placed on the cooked food indicating the following:

Food item name

Production cooking date

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48 hours shelf life

6.5 Food Storage

Food items are stored in

Shelves (dry food) (temperature to be maintained below 25°C)

Chillers (fresh, cooked, uncooked food) (temperature to be maintained at 0°C to 6°C)

Freezers (fresh, cooked, uncooked, pre-cooked, raw ) (temperature to be maintained at -18°C to -22°C)

Food Storage Areas:

Main Kitchen at T1

Main stores at Skycity

6.6 Food Defrosting

Food should never be thawed at room temperature, this increases the risk of bacteria and virus growth and the risk of food poisoning. Once thawed, food should be used and never refrozen.

Frozen food are defrosted using the following methods:

Microwave oven

During cooking

In cold draining water

In the chiller

6.7 Dry Storage of Foods

Vegetables

The guidelines vary for safe storage of vegetables under dry conditions (without refrigerating or freezing) according to the vegetables characteristics.

Example:

Cool and dry: onion

Cool and moist: root vegetable, potato, cabbage

Warm and dry: winter squash, pumpkin, sweet potatoes, dried hot peppers

Grain

Grain, which includes dry kitchen ingredients such as flour, rice, millet, couscous, cornmeal, and so on, can be stored in rigid closed containers (glass, plastic or metal) to prevent moisture contamination or insect or rodent infestation.

Spices and herbs

Spices and herbs are kept in plastic, glass or metallic containers for storage and dispensing purposed.

Spices and herbs can be preserved in vinegar or oil for short periods of up to a month, creating flavored vinegar or oil.

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Meat

Perishable meats should be refrigerated or frozen promptly.

Fish and shellfish

Perishable meats should be refrigerated or frozen promptly.

Food rotation

Food rotation is important to prevent expiry by following FIFO (First In First Out):

When storing, the fresher food must be placed at the back of the shelve.

When food is rotated, the food that has been in storage the longest is used first.

7. Food Operations Safety

7.1 Handling hazardous material

8. Procedures

8.1 Committee

8.2 Responsibilities

9. Framework (optional)

9.1 Committee

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9.2 Responsibilities

9.3 Functional areas

9.4 Operational areas

9.5 Stakeholders

10. Governance (optional)

10.1 Timeline

10.2 Action Register

10.3 Meetings

10.4 Executive Presentations

10.5 Processes

10.6 Administration (Scheduling, Meetings, MOMs, Documentation)

7. Business Process Documents

Forms:

Menu Specification Form

Missing Items Form

Registers

Risk Assessment Register

Incident Register

Cleaning Schedule Register

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Reports:

Monthly Supplier missing items

8. Record Keeping

Menus record using the Menu Specification Form

11. Budget (optional)

12. Responsibilities of Stakeholders

13. Potential Risks

This section is to provide a list of risks identified including danger and safety warnings in the event that should they occur, they would have an impact on the execution of tasks described in the Manual. The list should include the description of the risk and the impact level (to use color code if available). If not applicable, to mention N/A in this section.

14. Equipment and Material Required (optional)

This section is to provide a list of equipment and materials required for execution or compliance (e.g. PPE equipment, forklift, paint code).

15. Contact List (optional)

16. Lessons learnt (optional)

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17. Supporting Documentation and Tools

This section is to provide a list of documents and/or tools required to achieve the purpose of this Manual and its compliance (e.g. links to the documents, system, application used).

18. Filing and Distribution

This section is to specify information related to the filing location, access and distribution of this Manual.

19. Change Log

Version No.

Document Creation, Review, Approval and Change Tracking

Actioned by

(Name, Title, Department) Action Date

Change Effective

Date

V1.0

V2.0

20. Appendix

N.B. This document is UNCONTROLLED unless signed by an authorized person in the appropriate section of this document or viewed in Workflo! on ADACNet.