Hazard Analysis (Word 384KB)
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HAZARD ANALYSIS _________________________________________________________________________________________ AIMS To analyse potential food hazards within the food production system. To identify where the hazards may occur. To identify points that are critical to food safety. To specify control measures and acceptable ranges for the Critical Control Points (CCPs). To specify remedial action if CCP range is exceeded. To identify where the monitoring records for CCP controls are to be kept. INSTRUCTIONS Check the Catering Operational Flow Diagram to ensure it accurately reflects your own food production operation. For each stage that you have identified, the Hazard Identification sheet should be studied and any additional hazards, controls and CCPs written in (these are the points at which a food hazard can either be eliminated or reduced to a safe level). Specify the acceptable limits for the Critical Control Points and the corrective actions to be taken if these are not met. Utilise the Critical Control Points food safety monitoring forms. Completed monitoring forms must be available in order to provide evidence that these Critical Control Points are being monitored as well as helping to support the ‘due diligence’ defence. © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 1 HAZARD ANALYSIS _________________________________________________________________________________________ CATERING OPERATIONAL FLOWCHART PURCHASE STAGE 1 RECEIPT STAGE 2 STORAGE CHILLED, FROZEN, DRY GOODS STAGE 3 PREPARATION STAGE 4 STORAGE SERVE COLD STAGE 9 COOKING STAGE 5 COOKED TO ORDER BULK COOKING COOKED IN ADVANCE SERVE HOT HOLD HOT STAGE 7 CHILL STAGE 6 SERVE HOT CHILLED STORAGE SERVE COLD STAGE 9 REHEAT STAGE 8 SERVE HOT © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 2 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE ONE – PURCHASE 1. HAZARDS High risk foods contaminated with food poisoning bacteria or toxins. Foreign body contamination. Chemical contamination (pesticides, weedkillers, others). Excessive levels of spoilage bacteria on food. 2. CONTROLS Assessment and approval of suppliers before use. Utilisation of British Retail Consortium approved suppliers when ever possible Maintenance of a list of approved suppliers. Purchase of food only from approved suppliers. Setting of purchase specifications with suppliers including delivery temperatures and delivery conditions for high protein foods (meat, poultry, fish, shellfish, meat products and dairy products). Specification that products containing eggs which require no cooking, are made with pasteurised eggs. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT Selection of reputable suppliers MONITORING PROCEDURE Supplier specification letter Assessment of food safety information returned by suppliers ACCEPTABLE RANGE Food can only be obtained from approved suppliers CORRECTIVE ACTION Cancel order. Assess company under the Approved Suppliers system Assessment audits of suppliers of high risk food. © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 3 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE TWO – RECEIPT 1. HAZARDS High risk (high protein content and no further heat treatment necessary) foods contaminated with food poisoning bacteria or toxins. High risk foods contaminated with food spoilage bacteria or mould. Growth of food poisoning bacteria on high risk foods due to poor temperature control during transportation. Excessive levels of food poisoning bacteria on raw foods due to poor temperature control. Damage to packaging/cans with risk of bacterial and/or physical contamination. Contamination of food poisoning bacteria from raw foods onto high risk foods. 2. CONTROLS Visual and sensory checks of deliveries. Temperature control checks and records of deliveries of high risk foods and tuna. Temperature control checks of raw high protein foods where appropriate. Speedy transfer of deliveries into correct storage conditions. Checks of “use by” and “best before” dates for sufficient shelf life. Separation of raw and high risk foods. Trained staff for the receipt of foods. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT Receipt of high risk foods Receipt of all foods MONITORING PROCEDURE ACCEPTABLE RANGE Purchase from approved suppliers. Must be approved. Record delivery temperatures Chilled 1oC – 8oC Frozen -12oC to -18oC Purchase from reputable supplier Visual and sensory checks Absence of damaged packaging, pests, foreign bodies or mould Within use by date © FOOD ALERT LTD: WWW.FOODALERT.COM CORRECTIVE ACTION Inform manager/ Reject consignment Inform manager/ reject PAGE 4 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE THREE A- CHILLED STORAGE 1. HAZARDS Growth of food poisoning bacteria and production of toxins on high risk foods. Cross contamination of food poisoning bacteria from raw foods on to high risk foods. Foreign body contamination. Product deterioration/excessive shelf life. 2. CONTROLS Fridges operated between 1oC – 4oC and records kept. High risk foods stored separately from raw foods. Different fridges allocated to specific food types where possible, or raw foods to be stored BELOW high risk food. All foods stored in covered containers or wrapped. All prepared foods to be identified with a “use by” date. Date code labels to be checked and out of date stock to be discarded. Rotation of stock and use by specified date. Effective cleaning and sanitising of fridges with particular attention to handles and food containers. Regular maintenance and servicing of fridges. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT MONITORING PROCEDURE Storage temperature of high risk foods to be between 1oC and 4oC Record fridge operating temperatures Storage conditions and stock rotation of high risk foods Visual checks ACCEPTABLE RANGE 1oC - 8oC CORRECTIVE ACTION Inform manager Move foods to another fridge © FOOD ALERT LTD: WWW.FOODALERT.COM All high risk foods to be stored covered and dated No direct contact with raw foods to occur and no foreign bodies to be present. Adjust/repair fridge Inform manager Discard contaminated/out of date food PAGE 5 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE THREE B- FROZEN STORAGE 1. HAZARDS Growth of food spoilage bacteria and enzyme activity due to poor temperature control. Cross contamination of food poisoning bacteria from raw foods on to high risk foods. Product deterioration and physical contamination due to poor covering and excessive shelf life. 2. CONTROLS Frozen foods stored below –18oC. (Ice-cream in a service freezer can be held at -12oC for no longer than one month). High risk foods stored separately from raw foods. All foods stored in covered containers or thoroughly wrapped. All brought-in foods retain their original “best before” date and in-house produced foods identified with a “best before” date. Foods frozen on the premises to be provided with a “best before” date not exceeding 3 three months from date of freeze. Date code labels checked and out of date stock discarded. Stock rotate and use by specified date. No overloading of freezer. Effective cleaning and sanitising of freezers with particular attention to handles and grilles Effective defrosting of freezers. Regular maintenance and servicing of freezers 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT MONITORING PROCEDURE ACCEPTABLE RANGE Storage temperature of food in freezer below -18oC Recording of freezer temperatures daily Below – 15oC Storage condition of high risk foods Visual checks – audit. All foods to be stored covered and dated No contact with raw foods Within date © FOOD ALERT LTD: WWW.FOODALERT.COM CORRECTIVE ACTION If warmer than – 15oC manager informed and freezer temperature adjusted. Food move to another freezer unit Manager informed. Discarded contaminated/out of date food PAGE 6 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE THREE C- DRY GOODS STORAGE 1. HAZARDS Physical or chemical contamination. Contamination or infestation by pests Growth of food poisoning or spoilage bacteria and moulds. 2. CONTROLS All foods stored covered. Dry goods once opened stored in airtight, pest proof containers. “Best before” dates to be transferred when dry foods are decanted from original packaging. Store room kept clean, cool, dry, well ventilated and lit. Date labels checked and out of date stock discarded. Stock rotated and used by specified date. Packaging checked for signs of damage. No chemicals stored in food stores. Pest proofing of dry goods store. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT Food stored in dry goods store MONITORING PROCEDURE Visual inspections/ cleaning schedule ACCEPTABLE RANGE CORRECTIVE ACTION Stores to be clean and dry Clean store room Absence of foreign bodies Damaged, spoiled/ contaminated or infested food discarded Free from chemical contamination and taint Within date Out of date stock discarded Pests absent Pest control contract © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 7 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE FOUR A – PREPARATION 1. HAZARDS High risk foods contaminated with food poisoning bacteria or toxins. Growth of food poisoning bacteria on foods in ambient temperatures. Cross contamination of high risk foods with bacteria from raw foods. Cross contamination of high risk foods with bacteria from food handlers (hands, coughing etc.) Foreign body contamination. Chemical contamination. Use of contaminated equipment for high risk foods (chopping boards, knives, slicers etc.) 2. CONTROLS 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING Separate preparation areas/chopping boards for raw foods and high risk foods. Separate colour coded equipment and utensils for raw and high risk foods. Frequent cleaning and disinfection of all food contact/hand contact surfaces. Avoidance of excessive handling of high risk foods. High risk food kept at ambient temperatures for as short a time as possible. Good personal hygiene standards and training of staff. Cleaning, maintenance and checks of structure and equipment to prevent physical and bacterial contamination. “No glass” policy; food discarded near glass breakage Pest free environment. Safe use and storage of chemicals. CRITICAL CONTROL POINT MONITORING PROCEDURE Avoidance of cross contamination of high risk foods with food poisoning bacteria Visual checks Limiting of time food is exposed to ambient temperatures Food safety audits and inspection – use of probes Avoidance of physical/ chemical contamination Visual checks/Correct storage of chemicals Monitor cleaning schedule adherence © FOOD ALERT LTD: WWW.FOODALERT.COM ACCEPTABLE RANGE Complete separation of raw and high risk foods No contact of raw food with high risk food either directly or by means of a vehicle All food equipment to be cleaned and disinfected after use Food to be within 8o of storage temperature No physical/chemical contamination CORRECTIVE ACTION Contaminated food discarded Staff training Contaminated food discarded PAGE 8 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE FOUR B – THAWING 1. HAZARDS Growth of food poisoning bacteria and production of toxins. Cross contamination of food poisoning bacteria from raw foods on to high risk foods. Inadequate thawing. 2. CONTROLS Thawing carried out in temperature controlled conditions. It is preferable to use a thawer that operates between 12C and 16C. If this is not available, then foods should be thawed in the refrigerator. Complete separation of raw and high risk foods (at least raw foods under high risk foods). Labelling and use of thawed foods within 24 hours. Cleaning and disinfection of all equipment and surfaces. Controlled disposal of all thawed liquids. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT MONITORING PROCEDURE ACCEPTABLE RANGE CORRECTIVE ACTION Separation of raw and cooked/high risk foods Visual checks No contact Contaminated food discarded Thorough thawing Visual checks/sensory checks Completely thawed Continue thawing until completely thawed Prevention of contamination and cross contamination Visual checks All equipment and surfaces cleaned and disinfected Clean again Use promptly Visual checks of labelled food Within 24 hours Out of date food discarded Monitoring cleaning schedule © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 9 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE FOUR C – VACUUM PACKING 1. HAZARDS Bacterial or physical contamination from the packaging Growth of pathogenic anaerobic bacteria such as Clostridium perfringens and Clostridium botulinum Contamination from the packing machine 2. CONTROLS Use of food-grade packaging Covered storage of packaging Vacuum packed foods kept under chilled storage conditions below 5ºC Set shelf-life indicated by ‘use by’ date with regular checks of stock rotation controls “Consume within 3 days of opening” label Storage of vacuum packed foods away from raw foods Checking of seal integrity Regular cleaning and disinfection of the packing machine. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT MONITORING PROCEDURE ACCEPTABLE RANGE CORRECTIVE ACTION Correct seal on pack Visual check of pack Fully sealed pack Reseal pack Refrigerated storage of food Record fridge operating temperatures Below 5ºC Inform manager Move foods to another fridge Adjust/repair fridge Discard food over 10ºC © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 10 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE FOUR D – PRODUCTION 1. OF ICE CREAM HAZARDS Survival of food poisoning bacteria such as Salmonella species Growth of food poisoning bacteria 2. CONTROLS Use of pasteurised egg When raw eggs are used, ensuring ice cream mixtures achieve at least 65.5C for 30 minutes or 71.1C for 10 minutes or 79.4C for 15 seconds Ensuring the mixture is reduced to a temperature of not more than 7.2C within 1½ hours Thorough cleaning and disinfection of equipment High standards of personal hygiene 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINT Correct temperature control to avoid food poisoning survival (if raw egg is used) MONITORING PROCEDURE Probing of mix ACCEPTABLE RANGE CORRECTIVE ACTION At least 65.5C for 30 minutes Heat for longer Cooled to at least 7.2C with 1½ hours Cool quicker Growth of bacteria if mixture is not cooled quickly enough © FOOD ALERT LTD: WWW.FOODALERT.COM PAGE 11 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE FIVE – COOKING 1. HAZARDS Survival and growth of food poisoning bacteria. Formation of spores. Post cooking contamination by food poisoning bacteria. Foreign body contamination. 2. CONTROLS Thorough cooking to a core temperature of 70oC for 2 minutes (or 75C for 30 seconds). Separation of raw and cooked food. Use of clean and disinfected utensils. Covering of food where possible. Condition and maintenance of cooking equipment and utensils. Staff training. Effective pest control. Staff personal hygiene 4. CRITICAL CONTROL POINTS CRITICAL CONTROL POINTS Thorough cooking MONITORING PROCEDURES Cooking temperatures to be recorded © FOOD ALERT LTD: WWW.FOODALERT.COM ACCEPTABLE RANGE Core temperature of 70oC for 2 minutes (or 75C for 30 seconds) CORRECTIVE ACTION Continue to cook until specified temperature is achieved. PAGE 12 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE SIX – COOLING 1. HAZARDS Growth of any surviving food poisoning bacteria and germination of spores. Further contamination by food poisoning bacteria. Physical or chemical contamination. 2. CONTROLS EITHER rapid cooling of food in a blast chiller to below 5oC within 90 minutes and records kept. OR cooling of food in the coolest part of the kitchen use of ice trays, running water etc. for a maximum of 90 minutes before putting into the fridge and records kept. (delete as appropriate) Separation of raw and cooked foods. No covering of food during cooling process. Use of equipment that is clean, disinfected and in good repair. Effective pest control. Safe use and storage of chemicals. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINTS MONITORING PROCEDURES Cooling of high risk food Record time/temperature for cooling ACCEPTABLE RANGE Blast chiller: below 5oC within 1½ hours Ambient: coolest area used and food refrigerated within 1½ hours Cleanliness of equipment Cleaning schedules/ Visual checks Separation of raw and cooked foods Visual checks © FOOD ALERT LTD: WWW.FOODALERT.COM Only clean and disinfected equipment to be used No contact CORRECTIVE ACTIONS Manager informed Blast chiller adjusted Food chilled in smaller quantities Food discarded that has been left at ambient temperatures in excess of 2½ hours Clean again Contaminated food discarded Train staff PAGE 13 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE SEVEN – 1. HOT SERVICE HOLDING/DISPLAYING (EG. BAIN-MARIE, HOT CUPBOARD, HEATED DISPLAY, SOUP KETTLE) HAZARDS Post cooking contamination by food poisoning bacteria. Growth of spores, food poisoning bacteria and associated toxins. Cross contamination by food poisoning bacteria from raw food. Physical contamination. 2. CONTROLS Hold hot food at above 63oC. Food protected from further contamination (lids, sneeze screens etc.) Use of clean and disinfected containers and designated utensils. Service of food as quickly as possible. Disposal of leftovers. Regular observation for physical contaminants where appropriate. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINTS Temperature of food being held MONITORING PROCEDURES Record holding temperature of food ACCEPTABLE RANGE Above 63oC CORRECTIVE ACTIONS Manager informed Temperature of hot holding equipment adjusted Food reheated to above 700C Physical contamination Visual checks © FOOD ALERT LTD: WWW.FOODALERT.COM Absence of physical contaminants Contaminated food discarded PAGE 14 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE EIGHT – RE-HEATING 1. HAZARDS Survival of food poisoning bacteria and toxins. Physical contamination. 2. CONTROLS Thorough re-heating to a core temperature of 70oC for 2 minutes. Food only reheated once. Observation for physical contaminants. 3. CRITICAL CONTROL POINTS CRITICAL CONTROL POINTS MONITORING PROCEDURES Temperature of re-heated food Re-heated temperature of food recorded Above 70oC for 2 minutes Re-heated until target temperature is achieved. Physical contamination Visual checks Absence of physical contaminants Contaminated food discarded © FOOD ALERT LTD: WWW.FOODALERT.COM ACCEPTABLE RANGE CORRECTIVE ACTIONS PAGE 15 HAZARD ANALYSIS _________________________________________________________________________________________ STAGE NINE – COLD SERVICE HOLDING/DISPLAY (EG. COLD SERVERY COUNTER) 1. HAZARDS Cross contamination of high risk food with food poisoning bacteria. Growth of food poisoning bacteria on high risk food. Physical contamination. 2. CONTROLS EITHER high risk food held below 8oC. OR high risk food displayed at ambient temperatures for no longer than four hours. Raw and cooked food kept separate. Food protected from contamination by covering as far as possible. Use of clean and disinfected equipment and dedicated utensils. 3. CRITICAL CONTROL POINT MONITORING AND RECORD KEEPING CRITICAL CONTROL POINTS Correct storage temperature of high risk MONITORING PROCEDURES Service storage temperature recorded ACCEPTABLE RANGE 1oC - 8oC CORRECTIVE ACTIONS Manager informed Chiller adjusted Food moved to another unit Food protected from physical contamination Visual checks © FOOD ALERT LTD: WWW.FOODALERT.COM No physical contamination Contaminated food discarded PAGE 16
