haccp program application to specialized food processing · haccp terms haccp program: is ......

HACCP Program and Application to Specialized Food ProcessingCopyright 2008 1

HACCP PROGRAMHACCP PROGRAM&&

APPLICATION TO SPECIALIZED APPLICATION TO SPECIALIZED FOOD PROCESSINGFOOD PROCESSING

Olivia Andrade de Sanchez, EH SupervisorOlivia Andrade de Sanchez, EH SupervisorAlbuquerque Environmental Health Dept.Albuquerque Environmental Health Dept.

Albuquerque, New MexicoAlbuquerque, New MexicoOctober, 2008October, 2008

October, 2008 2HACCP PROGRAM & APPLICATIONS

OUTLINE:OUTLINE:

HISTORY AND COMMON TERMS.HISTORY AND COMMON TERMS.WHAT ARE HAZARDS?WHAT ARE HAZARDS?HACCP PRINCIPLESHACCP PRINCIPLESFOOD PROCESS CATEGORIESFOOD PROCESS CATEGORIESSPECIALIZED FOOD PROCESSING SPECIALIZED FOOD PROCESSING

MODIFIED OXYGEN PACKAGING (MOP)MODIFIED OXYGEN PACKAGING (MOP)


DEFINITIONDEFINITIONHH AZARDAZARDAA NALYSISNALYSISCC RITICALRITICALCC ONTROLONTROLPP OINTOINT

HACCP, a HACCP, a systematic systematic approach to the approach to the identification, identification, evaluation, and evaluation, and control of food control of food safety hazards. safety hazards.



A. HACCP HISTORYA. HACCP HISTORY

1960, Inception: For space program.1960, Inception: For space program.By: By:

NASANASAPillsbury Company and,Pillsbury Company and,US Army Natick Research and Dev. Labs.US Army Natick Research and Dev. Labs.

1982 1982 –– HACCP WITH 3 PRINCIPLES,HACCP WITH 3 PRINCIPLES,Hazard analysis, determination of CCP, and Hazard analysis, determination of CCP, and monitoring of CCPmonitoring of CCP


HACCP HISTORYHACCP HISTORY

1987 1987 –– Review by the National Advisory Review by the National Advisory Committee on Microbiological Criteria for Committee on Microbiological Criteria for Foods (NACMCF)Foods (NACMCF)1992 1992 -- NACMCF defined 7 widely NACMCF defined 7 widely acceptable principles that explain the acceptable principles that explain the HACCP process in detail.HACCP process in detail.19971997-- NACMCF adds emphasis to preNACMCF adds emphasis to pre--requisite programs. requisite programs.


HACCP APPLICATION HISTORY HACCP APPLICATION HISTORY

First used for:First used for:Low Acid and Canned Foods (LACF)Low Acid and Canned Foods (LACF)Infant formulaInfant formula

1997 1997 -- FDA applied for seafood and FDA applied for seafood and shellfish wholesale processors and shellfish wholesale processors and distributors, anddistributors, andPilot program for Retail Application, nonPilot program for Retail Application, non--regulatory.regulatory.



HACCP TERMSHACCP TERMS

HACCP Program: Is defined as a plan HACCP Program: Is defined as a plan designed to ensure that hazards are designed to ensure that hazards are prevented, eliminated or reduced to an prevented, eliminated or reduced to an acceptable level.acceptable level.A HACCP Program is a tool in food A HACCP Program is a tool in food production that can be used to achieve production that can be used to achieve active managerial control of risk factors. active managerial control of risk factors.


HACCP PROGRAM APPLICATIONHACCP PROGRAM APPLICATION

Specialized food processors at retail are Specialized food processors at retail are required to have a HACCP Program if:required to have a HACCP Program if:

A variance is granted at retail level, A variance is granted at retail level,

Operator is using one of the reduced oxygen Operator is using one of the reduced oxygen packaging (ROP) methods: MAP, RAP or, packaging (ROP) methods: MAP, RAP or, Sous vide.Sous vide.Using a specialized food processing method Using a specialized food processing method such as LACF, or vacuum packaging.such as LACF, or vacuum packaging.


HACCP Roles & PreHACCP Roles & Pre--requisites:requisites:

Roles:Roles: Operator is responsible for Operator is responsible for developing and implementing the HACCP developing and implementing the HACCP Plan and, regulator to audit.Plan and, regulator to audit.

PrePre--requisites:requisites: Operator must have:Operator must have:GMPs, SOP, and SSOPs.GMPs, SOP, and SSOPs.Control programs for: Employee health, Control programs for: Employee health, sanitation and pest control.sanitation and pest control.



B. WHAT IS A HAZARD?B. WHAT IS A HAZARD?

HAZARDHAZARD: Is a biological , chemical, or : Is a biological , chemical, or physical property that may cause a food to physical property that may cause a food to be unsafe for human consumption. be unsafe for human consumption. HAZARD CATEGORIESHAZARD CATEGORIES::

PHYSICAL,PHYSICAL,CHEMICAL AND, CHEMICAL AND, BIOLOGICAL.BIOLOGICAL.


TYPES OF HAZARDS:TYPES OF HAZARDS:

Physical HazardsPhysical Hazards::Glass,Glass,Metal,Metal,Wood,Wood,Plastic,Plastic,

etc. etc.

A HAZARD is not based on filth.A HAZARD is not based on filth.


CHEMICAL HAZARDSCHEMICAL HAZARDS

Chemical HazardsChemical Hazards: May be naturally : May be naturally occurring or added during the processing occurring or added during the processing of food.of food.

Natural: Histamine, aflatoxin.Natural: Histamine, aflatoxin.Man made: pesticides, sanitizers, Man made: pesticides, sanitizers, antibiotics.antibiotics.Allergen: As a food hazard, is a Allergen: As a food hazard, is a naturallynaturally--occurring protein in food or a occurring protein in food or a food ingredient.food ingredient.



ALLERGENS, CHEMICAL HAZARD:ALLERGENS, CHEMICAL HAZARD:

Allergens as a Allergens as a ““Food HazardFood Hazard”” have have different response symptoms:different response symptoms:

MildMild: Hives, itchy rashes, abdominal : Hives, itchy rashes, abdominal pain, vomiting and/or diarrhea.pain, vomiting and/or diarrhea.

Severe responseSevere response: anaphylactic shock : anaphylactic shock and death.and death.


BIOLOGICAL HAZARD:BIOLOGICAL HAZARD:

Biological hazards in foodBiological hazards in food

Bacterial pathogens are major cause Bacterial pathogens are major cause of food borne disease outbreaks. of food borne disease outbreaks.


C. HAACP PRINCIPLES:C. HAACP PRINCIPLES:

#1) Hazard Analysis#1) Hazard Analysis –– Determine the Determine the hazard that needs control and, the hazard that needs control and, the preventive control measures. preventive control measures.

You must identify the process to control You must identify the process to control or reduce the hazard. or reduce the hazard.



HAACP PRINCIPLE #1HAACP PRINCIPLE #1

Identification of HAZARDS: Identification of HAZARDS: Who?Who? Establishment HACCP Team, Establishment HACCP Team, What?What? Product description, Product description, Whom?Whom? Intended consumer, Intended consumer, Where?Where? Food Flow diagram, Food Flow diagram, Which?Which? Pertinent Hazard, by food flow Pertinent Hazard, by food flow or process.or process.Why?Why? Rational for inclusion/ exclusionRational for inclusion/ exclusion


Thermal Thermal processingprocessingCooling, cold Cooling, cold holding, drying and holding, drying and acidification.acidification.

Vacuum packed Vacuum packed foods, ROPs, foods, ROPs, canning, garliccanning, garlic--inin--oil, T/T abuseoil, T/T abuse

Clostridium Clostridium botulinumbotulinum

Proper cooking, Proper cooking, hand washing and hand washing and prevention of prevention of crosscross--contamination.contamination.

Poultry, raw milkPoultry, raw milkCamphilobacter Camphilobacter jejunijejuni

Proper cooking, Proper cooking, cooling, cold and cooling, cold and hot holding.hot holding.

Meat, poultry, Meat, poultry, starchy foods, starchy foods, puddings, cooked puddings, cooked vegetablesvegetables

Bacillus cereusBacillus cereusEmetic Emetic ––intoxicationintoxicationDiarrheal Diarrheal --InfectionInfection

CONTROL CONTROL MEASURESMEASURES

ASSOCIATED ASSOCIATED FOODSFOODS

BIOLOGICALBIOLOGICALHAZARDHAZARD


Cooking, date Cooking, date marking, cold marking, cold holding.holding.

Raw meat & Raw meat & poultry, soft poultry, soft cheeses, deli cheeses, deli meats, deli salads, meats, deli salads, pâtpâtéé

Listeria Listeria monocytogenesmonocytogenes

Cooking, No bareCooking, No bare--hand contact with hand contact with RTE foods. RTE foods. Pasteurization.Pasteurization.

Raw ground beef, Raw ground beef, raw seed sprouts, raw seed sprouts, raw milk, raw milk, unpasteurized unpasteurized juices, etc.juices, etc.

E.Coli O157:H7E.Coli O157:H7

Proper cooking, Proper cooking, cooling, hot cooling, hot holding and cold holding and cold holding.holding.

Cooked meats and Cooked meats and poultry, meat and poultry, meat and poultry casseroles, poultry casseroles, and graviesand gravies

Clostridium Clostridium perfringensperfringens






Cooking, cold / hot Cooking, cold / hot holding; prevent holding; prevent BHC with RTE foods.BHC with RTE foods.

RTE PHF touched by RTE PHF touched by bare hands as crossbare hands as cross--contaminationcontamination

Staphylococcus Staphylococcus aureusaureus

Cooking, NO BHC Cooking, NO BHC with RTE foods, and with RTE foods, and proper hand proper hand washing monitoring.washing monitoring.

Raw vegetables and Raw vegetables and herbs, food herbs, food contaminated by contaminated by infected workers infected workers (fecal /oral route)(fecal /oral route)

Shigella spp.Shigella spp.

Use of pasteurized Use of pasteurized milk, juices, eggs for milk, juices, eggs for HSP, no BHC with HSP, no BHC with RTE foods, RTE foods, employee sick policyemployee sick policy

Meat and poultry, Meat and poultry, seafood, eggs, raw seafood, eggs, raw seed sprouts, raw seed sprouts, raw milk, unpasteurized milk, unpasteurized juices.juices.

Salmonella spp.Salmonella spp.





CookingCookingBeef and porkBeef and porkTaenia spp.Taenia spp.

Cooking, freezing.Cooking, freezing.Fish (haddock, Fish (haddock, fluke, Pacific fluke, Pacific salmon, flounder, salmon, flounder, rock fish)rock fish)

PARASITES:PARASITES:Anisakis simplexAnisakis simplex

Cooking, approved Cooking, approved source, source, pasteurized pasteurized oysters, cold oysters, cold holding, prevention holding, prevention of crossof cross--contamination.contamination.

Seafood Seafood ShellfishShellfish

Vibrio spp.Vibrio spp.





NO BHC with RTE NO BHC with RTE foods; employee foods; employee health policy, hand health policy, hand washing.washing.

Any food Any food contaminated by contaminated by an infected worker an infected worker via fecal oral routevia fecal oral route

Rotavirus, Rotavirus, Norovirus, Norovirus, ReovirusReovirus

Approved source, Approved source, NO BHC with RTF, NO BHC with RTF, employee health employee health policies policies restrict/exclude.restrict/exclude.

Shellfish, any food Shellfish, any food contaminated by contaminated by an infected workeran infected worker

VIRUSES:VIRUSES:Hepatitis A and EHepatitis A and E

CookingCookingPork, bear, and Pork, bear, and seal meatseal meat

Parasites:Parasites:Trichenella spirallisTrichenella spirallis






Prohibited Prohibited consumption.consumption.Ethnic markets*Ethnic markets*

Puffer fish (Fugu or Puffer fish (Fugu or Blowfish)Blowfish)

TetrodoxinTetrodoxin

Approved source,Approved source,Origin verified (not Origin verified (not from an adverse from an adverse advisory.advisory.

Fin fish from Fin fish from Hawaii, SE US, Hawaii, SE US, tropical areas,tropical areas,Barracuda, Barracuda, mackerel. mackerel.

CiguatoxinCiguatoxin

Receiving Temps.Receiving Temps.Cold holding temps.Cold holding temps.Buyer Buyer specifications.specifications.

Tuna fish, blue fishTuna fish, blue fishAnchovies, Anchovies, mackerel.mackerel.Also, cheeseAlso, cheese

ScombrotoxinScombrotoxin(HISTAMINE)(HISTAMINE)



CHEMICAL CHEMICAL HAZARDHAZARD


Ensure Molluscan Ensure Molluscan shellfish are shellfish are properly tagged properly tagged and from approved and from approved source.source.

Molluscan shellfish Molluscan shellfish from NE & NW from NE & NW coastal regionscoastal regions

Shellfish toxins:Shellfish toxins:PSPPSPPARALYTIC PARALYTIC

Avoid unapproved Avoid unapproved source. Do not eat source. Do not eat unknown varieties.unknown varieties.

Numerous varieties Numerous varieties of wild mushroomsof wild mushrooms

Toxic mushroom Toxic mushroom speciesspecies

Check condition at Check condition at receiving.receiving.Avoid use of rotten Avoid use of rotten apples.apples.

Corn, corn Corn, corn products, peanuts, products, peanuts, & tree nuts. & tree nuts. Apple juiceApple juice

Mycotoxins:Mycotoxins:AflotoxinAflotoxinPafulinPafulin





Ensure Molluscan Ensure Molluscan shellfish are shellfish are properly tagged and properly tagged and from approved from approved source.source.

Molluscan shellfish Molluscan shellfish from NE, viscera of from NE, viscera of Dungeness, tanner, Dungeness, tanner, anchovies, red rock anchovies, red rock crabscrabs

Shellfish toxins:Shellfish toxins:ASPASP(Amnesic)(Amnesic)


Molluscan shellfish Molluscan shellfish from Golf of Mexicofrom Golf of Mexico

Shellfish toxins:Shellfish toxins:NSPNSP(NEUROLOGIC)(NEUROLOGIC)


Molluscan shellfish Molluscan shellfish from Japan, Chile, from Japan, Chile, NZ, Western Europe, NZ, Western Europe, & Eastern Canada& Eastern Canada

Shellfish toxins:Shellfish toxins:DSPDSP(DIARRETIC)(DIARRETIC)






Storage: proper Storage: proper chemical storage.chemical storage.Use only approved Use only approved chemicals.chemicals.

Any food may Any food may become become contaminatedcontaminated

Added chemicals:Added chemicals:Environmental Environmental contaminantscontaminants

Soak in water at Soak in water at least 5 hours. least 5 hours. Discard water. Boil Discard water. Boil in fresh water.in fresh water.

Undercooked or Undercooked or raw kidney beans.raw kidney beans.

PhylohaemmagglutPhylohaemmagglutinininin

Avoid herbs or Avoid herbs or foods containing foods containing these alkaloids.these alkaloids.

Avoid plant foods Avoid plant foods that contain these that contain these alkaloids. alkaloids. Leguminosa familyLeguminosa family

Naturally occurringNaturally occurringPyrrolizidine Pyrrolizidine alcaloidsalcaloids





Storage; Do not Storage; Do not store acid foods in store acid foods in copper utensils; copper utensils; backflow prevention backflow prevention device in vending device in vending machines.machines.

High acid foods and High acid foods and beveragesbeverages

Copper:Copper:Toxic elementToxic element

Pregnant women Pregnant women and children under 5 and children under 5 should not eat these should not eat these fish.fish.

Fish exposed to Fish exposed to organic mercury: organic mercury: shark, swordfish, shark, swordfish, King mackerel.King mackerel.

Mercury:Mercury:Toxic elementToxic element

Do not use Do not use chemicals not chemicals not allowed for use in allowed for use in human foods.human foods.

Numerous Numerous substances are substances are prohibited for prohibited for human human consumptionconsumption

Added chemicals:Added chemicals:Prohibited Prohibited substances (21 CFR substances (21 CFR 189)189)



CHEMICAL HAZARDCHEMICAL HAZARD


Sulfating agents Sulfating agents added to a added to a product must product must be declared on be declared on the label.the label.DO NOT add to DO NOT add to fresh fruits or fresh fruits or vegetables.vegetables.

Fresh fruits and Fresh fruits and vegetables.vegetables.Shrimp,Shrimp,Lobster, Lobster, WineWine

Preservatives Preservatives and food and food additives:additives:Sulfating agents Sulfating agents (sulfur dioxide, (sulfur dioxide, sodium and sodium and potassium potassium metabisulfites)metabisulfites)

Do not use Do not use containers w/ containers w/ lead or, inks on lead or, inks on packagingpackaging

High acid foods High acid foods and beverages.and beverages.

Toxic element:Toxic element:LeadLead






Address through Address through SOPs, for proper SOPs, for proper storage, labeling, storage, labeling, handling, and handling, and use. use. MSDS sheetsMSDS sheets

Any foods can Any foods can become become contaminatedcontaminated

Chemicals in Chemicals in retail retail

Address through Address through SOP for proper SOP for proper labeling, MSDA labeling, MSDA sheetssheets

Asian or Latin Asian or Latin foodsfoods

Flavor Flavor enhancers:enhancers:MSGMSG





Use of rigorous Use of rigorous sanitation regime sanitation regime to prevent crossto prevent cross--contamination contamination between between allergenic and allergenic and nonnon--allergenic allergenic ingredients.ingredients.

Foods Foods containing or containing or contacted by:contacted by:Milk,Milk,Egg,Egg,Fish,Fish,Crustacean Crustacean shellfishshellfishTree nuts,Tree nuts,Wheat,Wheat,Peanuts, andPeanuts, andSoybeansSoybeans

Allergens:Allergens:Natural protein in Natural protein in foodsfoods





HAACP PRINCIPLE #2HAACP PRINCIPLE #2CCP DeterminationCCP Determination: A step at which : A step at which control can be applied and is essential control can be applied and is essential to prevent, reduce or eliminate a hazard. to prevent, reduce or eliminate a hazard. (NACMCF, 1997).(NACMCF, 1997).

Meat casserole:Meat casserole:Hazard: biological => Hazard: biological => Clostridium Clostridium

perfringensperfringens..CCPs: Cooking, cooling, reheating CCPs: Cooking, cooling, reheating

and holding steps. and holding steps.



Decision Tree for a CCPDecision Tree for a CCP1)Preventive Measure

Necessary for the identified hazard?

Is control necessary at this step?

NO

2) Does it reduce, control or eliminate the hazard?

YES

CCP

Modify step, process or Product?

YES

NO

3) Contamination with identified hazard:Could it exceed or increase acceptable levels?

YES

YES4) Will a subsequent step eliminate or reduce identified

hazard, or reduce to an acceptable level?

NOSTOP! NOT A

CCP

NONO

YES


HACCP PRINCIPLE #3HACCP PRINCIPLE #3CRITICAL LIMIT:CRITICAL LIMIT: A maximum and /or A maximum and /or minimum value to which a biological, minimum value to which a biological, chemical or physical hazard must be chemical or physical hazard must be controlled at a CCP. To prevent, eliminate controlled at a CCP. To prevent, eliminate or reduce to an acceptable level the or reduce to an acceptable level the occurrence of a food safety hazard. occurrence of a food safety hazard.

A CL is based on science to ensure a hazard A CL is based on science to ensure a hazard is under control. It can be measured and be is under control. It can be measured and be quantifiable.quantifiable.

Meat in meat casserole: Beef cook to 70Meat in meat casserole: Beef cook to 70ººC (158C (158ººF)F)


HACCP PRINCIPLE #4HACCP PRINCIPLE #4

MonitoringMonitoring: Is a planned controlled : Is a planned controlled sequence of observations or sequence of observations or measurements to determine if a CCP is measurements to determine if a CCP is under control; an accurate record for under control; an accurate record for future use in verification .future use in verification .It must define who, what, when and where It must define who, what, when and where to measure accurately that the hazard was to measure accurately that the hazard was eliminated or reduced.eliminated or reduced.




Corrective actionCorrective action: Is a procedure : Is a procedure followed when deviation occurs. followed when deviation occurs.

Must be applied when: Must be applied when: Monitoring indicated a critical limit was Monitoring indicated a critical limit was exceeded, and,exceeded, and,If monitoring was not performed (it is unknown If monitoring was not performed (it is unknown if the critical limit was exceeded).if the critical limit was exceeded).



Corrective action should includeCorrective action should include: : To bring the process into compliance.To bring the process into compliance.

To ensure no PHF/TTCF products gets To ensure no PHF/TTCF products gets to the consumer if determined unsafe. to the consumer if determined unsafe.

If unsafe, determine the disposition of the If unsafe, determine the disposition of the nonnon--compliant product.compliant product.


HACCP PRINCIPLE #6HACCP PRINCIPLE #6Verification: Verification: Is the use of methods, Is the use of methods, procedures, or tests to determine if the procedures, or tests to determine if the implemented HACCP system is in implemented HACCP system is in compliance with the HACCP plan. compliance with the HACCP plan. Validation: Validation: Is the element of verification Is the element of verification focused on collecting and evaluating focused on collecting and evaluating information to determine if the HACCP information to determine if the HACCP Plan, if properly implemented, it controls Plan, if properly implemented, it controls the hazard. the hazard.




Establish Record Keeping ProceduresEstablish Record Keeping Procedures::Records provide documentation that:Records provide documentation that:

Corrective actions are executed when CL are Corrective actions are executed when CL are exceeded.exceeded.Operator exercised reasonable care to Operator exercised reasonable care to prevent a hazard during a FBI investigation.prevent a hazard during a FBI investigation.Examples: Equipment calibration records, Examples: Equipment calibration records, SSOP records; monitoring, corrective action, SSOP records; monitoring, corrective action, verification and validation records.verification and validation records.


HACCP Principle # 7:HACCP Principle # 7:

Record keeping, is used to:Record keeping, is used to:Document compliance with the HACCP Plan,Document compliance with the HACCP Plan,Show trends,Show trends,Measure accuracy,Measure accuracy,Evaluate if documentation is complete, Evaluate if documentation is complete, Provide historical evidence,Provide historical evidence,Document if hazards are controlled or Document if hazards are controlled or eliminated.eliminated.


HACCP AUDITS vs INSPECTIONSHACCP AUDITS vs INSPECTIONS

INSPECTIONS:INSPECTIONS:OBSERVATIONSOBSERVATIONS

RECORD REVIEWRECORD REVIEW

INTERVIEWSINTERVIEWS

SAMPLES/EXAMSAMPLES/EXAM

MEASURINGMEASURING

SPECIFICATIONSSPECIFICATIONS

PHOTOSPHOTOS

PROCESS PROCESS INSPECTIONINSPECTION

HACCP AUDITS:HACCP AUDITS:VERIFICATIONVERIFICATION

REVIEW OF REVIEW OF RECORDSRECORDS

INTERVIEWSINTERVIEWS

OBSERVATIONSOBSERVATIONS

SYSTEMS VS SYSTEMS VS PROCESS REVIEW.PROCESS REVIEW.

PLANS VALIDATIONPLANS VALIDATION



C. HACCP PROCESS APPROACHC. HACCP PROCESS APPROACH

Hazard analysis is done by food Hazard analysis is done by food preparation process common to the retail preparation process common to the retail operation. operation. It divides the many food flows into broad It divides the many food flows into broad categories based on activities.categories based on activities.Identified hazards are analyzed by placing Identified hazards are analyzed by placing managerial controls on each grouping.managerial controls on each grouping.


HACC PROCESS APPROACHHACC PROCESS APPROACH

Grouping is based on how many times Grouping is based on how many times food passes the danger zone (41food passes the danger zone (41ºº and and 135135ºº):):

Process 1) No-cook Step

Process 2) Same Day Service (cook n serve)Process 2) Same Day Service (cook n serve)

Process 3) Complex Food PreparationProcess 3) Complex Food Preparation


GROUPING BY DANGER ZONE GROUPING BY DANGER ZONE ““DZDZ”” EXPOSUREEXPOSURE

Process 1) Process 1) NoNo--cook Stepcook Step ““00”” DZ DZ exposures.exposures.

Process 2) Process 2) Same Day ServiceSame Day Service 1 DZ 1 DZ exposure.exposure.

Process 3) Process 3) Complex Food PreparationComplex Food Preparation::Up to Up to ““33”” DZ exposures /passes through the DZ exposures /passes through the danger zone.danger zone.



HACCP HACCP –– PROCESS 1PROCESS 1

Process 1) Process 1) NoNo--cook Stepcook Step ““00”” DZ DZ exposures.exposures.

Receive Receive →→ Store Store →→ Prepare Prepare →→ HoldHold→→Serve.Serve.

There may be variations or other food flows.There may be variations or other food flows.But, there is no cook step to destroy pathogens!But, there is no cook step to destroy pathogens!



Process 2) Process 2) Same Day ServiceSame Day Service ““11”” DZ DZ exposures.exposures.Receive Receive →→ Store Store →→ Prepare Prepare →→ CookCook

↓↓ServeServe←←HoldHold

Variations to order of food flow may exist but only Variations to order of food flow may exist but only on trip or exposure through the danger zone on trip or exposure through the danger zone (DZ).(DZ).



Process 3) Process 3) Complex Food ProcessingComplex Food Processing: : Receive Receive →→ Store Store →→ Prepare Prepare →→ CookCook→→

CoolCool↓↓ServeServe←← Reheat Reheat

Variations to order of food flow may exist but Variations to order of food flow may exist but there are always two or three trips through DZ.there are always two or three trips through DZ.



HACCP HACCP –– PROCESS PROCESS variationsvariations

The 3 Process approach is not all inclusive. The 3 Process approach is not all inclusive. Cook and serveCook and serve: Common to quick : Common to quick service facilities. Process may include:service facilities. Process may include:Receive Receive →→ Store Store →→ Prepare Prepare →→ ReheatReheat

↓↓Hold Hold →→ Serve.Serve.


Hazard Analysis to a HACCP Hazard Analysis to a HACCP ProcessProcess

Menu item specific HACCP hazard analysis is time Menu item specific HACCP hazard analysis is time consuming, labor intensive and unnecessary.consuming, labor intensive and unnecessary.

HACCP Food Flow and Process Approach:HACCP Food Flow and Process Approach:Groups menu items into 3 process categories.Groups menu items into 3 process categories.Group within process by Group within process by type of foodtype of food. .

Example: Beef, poultry, pork, vegetables.Example: Beef, poultry, pork, vegetables.Identifies hazard by Identifies hazard by type of food or processtype of food or process..Identifies control measures by grouping.Identifies control measures by grouping.


Hazard Analysis to a HACCP Hazard Analysis to a HACCP Food ProcessFood Process

Example: Example: No Cook Step ProcessNo Cook Step ProcessGrouping by Grouping by type of food: Deli meats, type of food: Deli meats, dairy products (cheese, creams, yogurt), dairy products (cheese, creams, yogurt), produceproduce..OtherOther: Raw ready: Raw ready--toto--eat foods: sashimi, eat foods: sashimi, raw oysters, and salads. raw oysters, and salads. Common Food Flow:Common Food Flow:

Receive Receive →→Store Store →→Prepare Prepare →→Hold Hold →→ServeServe



Hazard Analysis to a HACCP Hazard Analysis to a HACCP Food Process: 1Food Process: 1

No Cook Step ProcessNo Cook Step ProcessFood Flow, example:Food Flow, example:

Receive Receive →→Store Store →→Prepare Prepare →→Hold Hold →→ServeServe(NO KILL STEP (NO KILL STEP –– Hazard: contamination)Hazard: contamination)


Hazard Analysis to a HACCP Hazard Analysis to a HACCP Food Process: No Cook StepFood Process: No Cook StepNo Cook Step Process / Food FlowNo Cook Step Process / Food Flow

Common Managerial Controls:Common Managerial Controls:Approved sourceApproved sourceCold Holding: Cold Holding: Control bacterial growth and Control bacterial growth and toxin production. toxin production. Receiving Temperatures: Receiving Temperatures: ScombrotoxinScombrotoxin


Hazard Analysis to a HACCP Hazard Analysis to a HACCP Food Process: No Cook Step, Food Process: No Cook Step,

cont.cont.No Cook Step Process / Food FlowNo Cook Step Process / Food Flow

Common Managerial Controls:Common Managerial Controls:Date Marking: Date Marking: First in, first out (FIFO)First in, first out (FIFO)

Control of psychrophiles: Control of psychrophiles: Listeria Listeria monocytogenesmonocytogenes

Freezing: Freezing: Required for certain species of Required for certain species of fish for parasite destruction.fish for parasite destruction.Cooling: Cooling: From ambient temperature to From ambient temperature to prevent sporeprevent spore--forming or toxicforming or toxic--forming forming bacterial growth.bacterial growth.




Same Day Service Same Day Service -- Common food flow:Common food flow:ReceiveReceive→→ StoreStore→→ PreparePrepare→→ CookCook→→ Hold Hold →→ServeServe

Biological Hazard: Control measures Biological Hazard: Control measures COOKINGCOOKING food to the proper temperature,food to the proper temperature,PROPER HOT HOLDING PROPER HOT HOLDING for sporefor spore--formers.formers.



Same Day Service Same Day Service -- Common food flow:Common food flow:ReceiveReceive→→ StoreStore→→ PreparePrepare→→ CookCook→→ Hold Hold →→ServeServe

Type of food: Type of food: Baked chicken and stuffed meatloaf.Baked chicken and stuffed meatloaf.Identified biological hazards:Identified biological hazards:

Salmonella spp., and E. coli O157:H7Salmonella spp., and E. coli O157:H7Spore formers: Spore formers: Bacillus cereus and Clostridium Bacillus cereus and Clostridium perfringens. perfringens.

Control measures by grouping:Control measures by grouping:Both, Both, COOKINGCOOKING to 165to 165ººFFFor spore formers, proper hot holding to 135For spore formers, proper hot holding to 135ººFF


Hazard Analysis to a HACCP Hazard Analysis to a HACCP Food ProcessFood Process

Example: Example: Same Day Service ProcessSame Day Service ProcessGrouping by type of food: Poultry (chicken) Grouping by type of food: Poultry (chicken) and ground beef (meatloaf)and ground beef (meatloaf)..Identifies control measures CL for CCP:Identifies control measures CL for CCP:Common CCP involve time/temperature controls: Common CCP involve time/temperature controls: Cooking, holding, reheating & cooling.Cooking, holding, reheating & cooling.Prevention of CrossPrevention of Cross--contamination:contamination:

Hands or employees as a vehicle of contamination.Hands or employees as a vehicle of contamination.Equipment and Environmental Controls.Equipment and Environmental Controls.



Same Day Service ProcessSame Day Service Processby Type of Foodby Type of Food

Poultry: Poultry: Critical limits:Critical limits:Refrigeration: 5Refrigeration: 5ººC(41C(41ººF)F)Cooking: 74Cooking: 74ººC (165C (165ººF) F)

for 15 sec.for 15 sec.Hot holding: > 57Hot holding: > 57ººC C (135(135ººF)F)

or time control.or time control.

Good personal hygiene:Good personal hygiene:NO BHC with RTE food.NO BHC with RTE food.Exclude or restrict ill Exclude or restrict ill employees.employees.

Ground beef: Ground beef: Critical limits:Critical limits:Refrigeration: 5Refrigeration: 5ººC(41C(41ººF) F) Cooking: 68.3Cooking: 68.3ººC (155C (155ººF)/ F)/ 15 sec.15 sec.Hot holding: >57Hot holding: >57ººC (135C (135ººF)F)or time control.or time control.Good personal hygiene:Good personal hygiene:

NO BHC with RTE food.NO BHC with RTE food.Exclude or restrict ill Exclude or restrict ill employeesemployees..


Hazard Analysis to a HACCP Hazard Analysis to a HACCP Complex Food ProcessComplex Food Process

ReceiveReceive→→ StoreStore→→ PreparePrepare→→ CookCook→→ Hold Hold →→→→Cool Cool →→Reheat Reheat →→Hot Hold Hot Hold →→ ServeServe

Identified biological hazards:Identified biological hazards: Due to Due to multiple passes through the DZ lead to multiple passes through the DZ lead to spore formers.spore formers.

Spore formersSpore formers: : Bacillus cereus and Bacillus cereus and Clostridium perfringens.Clostridium perfringens.


Complex Food Process ControlsComplex Food Process Controls

Holding tempsHolding temps: Cold and : Cold and HotHot

Bacterial Growth and Bacterial Growth and Toxin formation. Toxin formation.

Cooking: Cooking: Destroy bacteria & Destroy bacteria & parasites.parasites.

CoolingCooling: : SporeSpore--forming forming & toxin production.& toxin production.

Date marking:Date marking:RTE foods control of RTE foods control of psychrophiles.psychrophiles.

Reheating for Hot Reheating for Hot Holding:Holding:

Destroy vegetative cells.Destroy vegetative cells.

Approved food source:Approved food source:Receiving,Receiving,Cold holding for marine Cold holding for marine finfish (ciguatera toxin and finfish (ciguatera toxin and scombrotoxin).scombrotoxin).


D. HACCP APPLICATION:D. HACCP APPLICATION:

SPECIALIZED FOOD PROCESSINGSPECIALIZED FOOD PROCESSING


FOOD PROCESSING CRITERIA:FOOD PROCESSING CRITERIA:

REDUCED OXYGEN PACKAGINGREDUCED OXYGEN PACKAGING::FC Section 3FC Section 3--502.12: HACCP Plan required.502.12: HACCP Plan required.FC 3FC 3--502.11 & 8502.11 & 8--103.11: Operator must 103.11: Operator must obtain a Variance from the Regulatory obtain a Variance from the Regulatory Authority. Evaluate / Audited annually.Authority. Evaluate / Audited annually.

Required: Written GMP, SOP, SSOP prior to Required: Written GMP, SOP, SSOP prior to HACCP Plan approval.HACCP Plan approval.


FOOD PROCESSING CRITERIA:FOOD PROCESSING CRITERIA:

REDUCED OXYGEN PACKAGING REDUCED OXYGEN PACKAGING ((ROP)ROP) Is a packaging procedure that Is a packaging procedure that results in a reduced oxygen level in a results in a reduced oxygen level in a sealed package. To include:sealed package. To include:

CookCook--chillchillControlled Atmosphere Packaging (Controlled Atmosphere Packaging (CAPCAP),),Modified Atmospheric Packaging (Modified Atmospheric Packaging (MAPMAP),),SousSous--VideVide, specialized ROP for partially , specialized ROP for partially cooked ingredients.cooked ingredients.



ROP TERMSROP TERMS

CookCook--chill:chill: The use of a plastic bag filled The use of a plastic bag filled with hot cooked food, air expelled and with hot cooked food, air expelled and closed with a metal clip or sealed. closed with a metal clip or sealed. ControlledControlled--atmosphere Packaging (CAP);atmosphere Packaging (CAP);““An active system that continuously An active system that continuously maintains the desired atmosphere to maintains the desired atmosphere to reduce or scavenge oxygen.reduce or scavenge oxygen.””


ROP TERMSROP TERMS

CookCook--chill:chill: The use of a plastic bag filled The use of a plastic bag filled with hot cooked food, air expelled and with hot cooked food, air expelled and closed with a metal clip or sealed. closed with a metal clip or sealed. Controlled Atmosphere Packaging (CAP):Controlled Atmosphere Packaging (CAP):““An active system that continuously An active system that continuously maintains the desired atmosphere to bind maintains the desired atmosphere to bind or scavenge oxygen.or scavenge oxygen.””


ROP TERMSROP TERMS

Modified Atmosphere Packaging (MAP): Modified Atmosphere Packaging (MAP): ““A packaging process of a product in an A packaging process of a product in an

atmosphere which has oneatmosphere which has one--time time modification of gaseous composition to a modification of gaseous composition to a composition different than air; which has composition different than air; which has 78.0% Nitrogen, 20.96% oxygen and 78.0% Nitrogen, 20.96% oxygen and 0.03% carbon dioxide.0.03% carbon dioxide.””



ROP TERMSROP TERMS

Sous vide, specialized process of ROP Sous vide, specialized process of ROP ““Packaging process of partially cooked food Packaging process of partially cooked food

alone or mixed with raw foods that require alone or mixed with raw foods that require refrigeration or freezing.refrigeration or freezing.””

Sous vide is a pasteurization step that Sous vide is a pasteurization step that reduces bacterial growth BUT NOT reduces bacterial growth BUT NOT sufficient to make food shelf stable.sufficient to make food shelf stable.


ROP TERMSROP TERMS

Vacuum packaging (VP)Vacuum packaging (VP): Reduces the : Reduces the amount of air from a package and amount of air from a package and hermetically seals the package, to create a hermetically seals the package, to create a near perfect vacuum seal.near perfect vacuum seal.

Variation: Variation: Vacuum Skin Packaging (VSP)Vacuum Skin Packaging (VSP)Using a flexible plastic barrier that mold to Using a flexible plastic barrier that mold to the food being packaged.the food being packaged.


ROP ROP -- Benefits:Benefits:

ROP can: ROP can: Create an anaerobic environment to prevent Create an anaerobic environment to prevent growth of aerobic/spoilage bacteria & molds.growth of aerobic/spoilage bacteria & molds.Prevents degradation or oxidative process in Prevents degradation or oxidative process in food products. food products. Prevents color deterioration in raw meats Prevents color deterioration in raw meats caused by oxygen.caused by oxygen.Prevents product shrinkage by reduced water Prevents product shrinkage by reduced water loss.loss.



ROP ROP –– Safety Concerns:Safety Concerns:

ROP ROP increase safety concerns.increase safety concerns.1) Psychrotrophic bacteria: Adequate 1) Psychrotrophic bacteria: Adequate refrigeration required for ROP.refrigeration required for ROP.

55ººC(41C(41ººF) of below to prevent growth.F) of below to prevent growth.

2) Control Clostridium botulinum and, Listeria 2) Control Clostridium botulinum and, Listeria monocytogenes.monocytogenes.

Botulism toxin may survive after thermal Botulism toxin may survive after thermal pasteurization, souspasteurization, sous--vide products (partial cooking)vide products (partial cooking)



ROP ROP increase safety concerns.increase safety concerns.3) Design of heat Processes for Foods in 3) Design of heat Processes for Foods in ROP:ROP:

SousSous--vide process practiced in Europe is designed vide process practiced in Europe is designed to achieve a 12to achieve a 12--13 D thermal death reduction of 13 D thermal death reduction of Streptococcus faecalis. Most products are blast Streptococcus faecalis. Most products are blast freeze packaged and kept at < 5freeze packaged and kept at < 5ººC(41C(41ººF).F).



ROP ROP increase safety concerns.increase safety concerns.Time/temperature control for safety foods Time/temperature control for safety foods ((TCSTCS) packaged with ROP process may ) packaged with ROP process may increase microbial growth if temperature increase microbial growth if temperature abused.abused.Process must incorporate safety barriers:Process must incorporate safety barriers:

pH, Aw, or salt concentrations if no preservatives pH, Aw, or salt concentrations if no preservatives used.used.Note: Vacuum packaging of smoked fish Note: Vacuum packaging of smoked fish prohibited.prohibited.



ROP Temperature concerns:ROP Temperature concerns:

Anaerobic conditions after ROP packaging Anaerobic conditions after ROP packaging promote:promote:

Growth of psychrotrophic microorganisms.Growth of psychrotrophic microorganisms.Refrigeration =/< 3Refrigeration =/< 3ººC(38C(38ººF) to control Listeria F) to control Listeria monocytogenes.monocytogenes.ROP processing must reach a 4D (decimal log ROP processing must reach a 4D (decimal log reduction) of Listeria monocytogenes.reduction) of Listeria monocytogenes.

Safety barriers: pH, Aw, and short shelf life,Safety barriers: pH, Aw, and short shelf life,Strict monitoring of cold holding procedures.Strict monitoring of cold holding procedures.


ROP Temperature concerns:ROP Temperature concerns:

Heat process concerns for foods in ROP:Heat process concerns for foods in ROP:Sous vide and cookSous vide and cook--chill operations must be chill operations must be designed to destroy vegetative pathogens designed to destroy vegetative pathogens during pasteurization.during pasteurization.

NACMCF recommends that an ROP process NACMCF recommends that an ROP process demonstrate the ability to inactivate L. demonstrate the ability to inactivate L. monocytogenes to achieve a 4 log reduction (4D).monocytogenes to achieve a 4 log reduction (4D).Determination by microbial studies.Determination by microbial studies.Special labeling instructions for consumers.Special labeling instructions for consumers.


ROP ROP –– Safety Barrier Verification:Safety Barrier Verification:

Operations for all processed foods held in Operations for all processed foods held in ROP at retail SHALL have written ROP at retail SHALL have written certification from the product certification from the product manufacturer.manufacturer.

Changes to product formulation or processing Changes to product formulation or processing procedures are to be notified to the procedures are to be notified to the Regulatory Authority.Regulatory Authority.Safety barrier verification should be updated Safety barrier verification should be updated every 12 months.every 12 months.



ROP ROP –– Safety Barrier VerificationSafety Barrier Verification

Exemptions:Exemptions:99--CFR424, Meat and poultry products CFR424, Meat and poultry products

cured at a food processing plant regulated cured at a food processing plant regulated by the US Department of Agriculture by the US Department of Agriculture (USDA). (USDA).


ROP ROP –– Without Multiple BarriersWithout Multiple Barriers

Recommendations:Recommendations:Employee training,Employee training,Refrigeration requirements: Label and Refrigeration requirements: Label and date with date with ””UseUse--by Dateby Date”” refrigerate at refrigerate at < 5< 5ººC(41C(41ººF)F), , or 14 days after or 14 days after preparation at retailpreparation at retail.. Below 3Below 3ººC(38C(38ººF) F) beyond 14 days.beyond 14 days.


ROP ROP –– Without Multiple BarriersWithout Multiple Barriers

Recommendations, continuation:Recommendations, continuation:Labeling statement: Must say: Labeling statement: Must say: ““Important Important –– Must be kept refrigerated Must be kept refrigerated at < 5at < 5ººC(41C(41ººF) 41F) 41ººFF”” or say or say ““Must be Must be kept frozenkept frozen”” on the principal display on the principal display panel.panel.



Food Products Food Products –– Variance Variance RequirementRequirement

Processed fish and smoked fish, may not Processed fish and smoked fish, may not be packaged in ROP. Only if premises are be packaged in ROP. Only if premises are approved for this activity and approved by approved for this activity and approved by regulatory authority and has a scheduled regulatory authority and has a scheduled process established. process established. Soft cheeses such as ricotta, cottage Soft cheeses such as ricotta, cottage cheese, cheese spreads and cheese, cheese spreads and combinations. Process must be approved.combinations. Process must be approved.



Smoked or cured meat and poultry, Smoked or cured meat and poultry, at retail, mat retail, must have a HACCP Plan ust have a HACCP Plan approved by the Regulatory approved by the Regulatory authority. authority.



Other food processing that require a Other food processing that require a HACCP and regulatory Variance are:HACCP and regulatory Variance are:

Fermentation, to reduce pH <4.6. Fermentation, to reduce pH <4.6. Dehydration to reduce Aw to < 0.85.Dehydration to reduce Aw to < 0.85.

Hazards: Hazards: Product contamination, employee hygieneProduct contamination, employee hygieneProduct specific treatments. Product specific treatments.



REFERENCES:REFERENCES:United States U.S. Department of health And United States U.S. Department of health And Human Services. Food Code. 2005 ed. College Human Services. Food Code. 2005 ed. College Park, MD:GPO 2005.Park, MD:GPO 2005.Association of Food and Drug Officials, 1990. Association of Food and Drug Officials, 1990. Retail Guidelines. Refrigerated Foods in Retail Guidelines. Refrigerated Foods in Reduced Oxygen Packages. Reduced Oxygen Packages. J. Assoc. Food and J. Assoc. Food and Drug Officials. 54(5):80Drug Officials. 54(5):80--8484Schmidt, Ronald and Rodrick, Gary Schmidt, Ronald and Rodrick, Gary ““Implementation of FSIS Regulatory Programs Implementation of FSIS Regulatory Programs for Pathogen Reduction,for Pathogen Reduction,”” Food Safety Food Safety HandbookHandbook, 2003, pp. 325, 2003, pp. 325--336336

haccp program application to specialized food processing · haccp terms haccp program: is ......

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