Section 3 Process Control using HACCP Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Table of Contents INTRODUCTION .............................................................................................................. 4 PRODUCT DESCRIPTION AND INTENDED USE ........................................................... 5 SAMPLE RISK ANALYSIS CHART — RECEIVE ............................................................ 6 SAMPLE RISK ANALYSIS CHART — DRY STORE ....................................................... 7 SAMPLE RISK ANALYSIS CHART — COLD STORE .................................................... 8 SAMPLE RISK ANALYSIS CHART — FREEZING .......................................................... 9 SAMPLE RISK ANALYSIS CHART — DEFROST ..........................................................11 SAMPLE RISK ANALYSIS CHART — ISSUE ................................................................12 SAMPLE RISK ANALYSIS CHART — PREPARATION .................................................13 SAMPLE RISK ANALYSIS CHART — COOK ................................................................15 SAMPLE RISK ANALYSIS CHART — HOT HOLD ........................................................16 SAMPLE RISK ANALYSIS CHART — SERVE HOT ......................................................17 SAMPLE RISK ANALYSIS CHART — COOL ................................................................18 SAMPLE RISK ANALYSIS CHART — REHEAT ............................................................19 SAMPLE RISK ANALYSIS CHART — COLD HOLD......................................................20 SAMPLE RISK ANALYSIS CHART — SERVE COLD....................................................21 SAMPLE RISK ANALYSIS CHART — DISPATCH.........................................................22 HACCP AUDIT TABLES .................................................................................................24 Prepare–cook–hold–serve 25 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 25 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 28 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 30 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 31 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 32 Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 33 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 34 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes 35 Cook to order meat, fish, chicken, pasta, rice 36 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice 37 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice 39 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice 41 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice 42 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice 43 Egg-based products 44 Model HACCP Audit Table: Cook–hold–serve — eggs/egg-based products 45 Model HACCP Audit Table: Cook–hold–serve — eggs/egg-based products 46 Model HACCP Audit Table: Cook–hold–serve — eggs/egg-based products 47 Model HACCP Audit Table: Cook–hold–serve — Eggs/egg-based products 48 Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Introduction This is an example of a Food Safety Manual that has been developed to assist your learning of HACCP-based food safety programs. The development of food safety programs based on the principles of the hazard analysis critical control point (HACCP) system is the most effective way of ensuring food safety. The manual is intended to be a very general guide for HACCP-based food safety programs that will show you how all the parts of the food safety program come together. This manual is an example of a HACCP-based food safety program for food service processes that include: cook serve cook chill reheat serve (not extended shelf life cook chill). We have taken every effort to ensure that the sample guidelines in this manual meet the minimum standard for food safety for the processes described. However, when using these guidelines you need to undertake your own research to be assured that you have met current food safety standards and industry codes for the operations undertaken by the business for which you work. This section of the manual describes the Process Controls using HACCP. The first part is made up of a series of Risk Analysis Charts that list a procedure (eg dry store) and identify the possible hazards as well as the preventative measures to be followed. The second part of this section includes sample HACCP Audit Tables that are designed to indicate the monitoring required for each step of the food production process. Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Product description and intended use Food produced by the business will be: prepared by kitchen staff consumed on the day of production or chilled and used within 48 hours or frozen for later use dispatched to be used off site. Product Description and Intended Use Composition Ready-to-eat meat, fish, chicken, pasta and rice dishes Ready-to-eat egg dishes Storage conditions Chilled at 5C or below Frozen to –18C Intended use Consumed by customers immediately after service Packaging primary Food grade alfoil, plastic bags and containers Packaging secondary Plastic tubs and cardboard cartons Shelf life Daily distribution — use within 48 hours Frozen goods as per the item Distribution method Refrigerated van Sensitive clients Service to the general public. No specific at risk groups Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Sample Risk Analysis Chart — Receive RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous foods Ready to cook hazardous foods Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Receive chilled products at a temperature at or below 5°C Frozen products must be received frozen Chemical L L L Supplier specifications Physical L L L Visual check and discard as appropriate Biological H H H Receive chilled products at a temperature at or below 5°C Frozen products must be received frozenVisual check and discard as appropriate Chemical L L L Supplier specifications Physical L L L Visual check and discard as appropriate Biological L L L Visual check Chemical L L L Supplier specifications Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 6 Sample Risk Analysis Chart — Dry Store RISK ASSESSMENT INPUT/CONTROL Non-hazardous foods Key: H = High M = Medium HAZARDS PREVENTATIVE MEASURE Severity Risk Significance Biological L L L Store products according to specifications and individual food requirements Chemical L L L Storage specifications Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 7 Sample Risk Analysis Chart — Cold Store RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Ready to cook hazardous food Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Store chilled products at or below 5°C Store frozen products below -18°C Physical L L L Visual check and discard as appropriate Biological H H H Store chilled products at or below 5°C Store frozen products below –18°C Physical L L L Visual check and discard as appropriate Biological L L L Store products according to specifications and individual food requirements Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 8 Sample Risk Analysis Chart — Freezing RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Ready to cook hazardous food Egg-based products Non-hazardous foods HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Reduce internal temperature of food from 60°C to 21°C within two hours and from 21°C to 5°C or below within a further four hours Freeze food to below -18°C and maintain temperature below -18°C during frozen storage Physical L L L Visual check and discard as appropriate Biological H M M Reduce internal temperature of food from 60°C to 21°C within two hours and from 21°C to 5°C or below within a further four hours Freeze food to below -18°C and maintain temperature below -18°C during frozen storage Physical L L L Visual check and discard as appropriate Biological H H H Reduce internal temperature of food from 60°C to 21°C within two hours and from 21°C to below 5°C within a further four hours Freeze food to below -18°C and maintain temperature below -18°C during frozen storage Physical L L L Visual check and discard as appropriate Biological L L L Freeze food to below -18°C and maintain temperature below -18°C during frozen storage Physical L L L Visual check and discard as appropriate Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 9 Key: H = High M = Medium L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 10 Sample Risk Analysis Chart — Defrost RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Ready to cook hazardous food Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Follow correct defrosting procedures Defrost in refrigerator Thawed cooked food is not to be refrozen Physical L L L Visual check and discard as appropriate Biological H M M Follow correct defrosting procedures Defrost in refrigerator Thawed raw food is not to be refrozen Physical L L L Visual check and discard as appropriate Biological L L L Defrost according to product requirements and manufacturer’s directions Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 11 Sample Risk Analysis Chart — Issue RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous foods Ready to cook hazardous foods Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Maintain chilled products at or below 5°C Frozen products must remain frozen Food to be out of fridge/freezer for no more than 20 minutes Physical L L L Visual check and discard as appropriate Biological H M M Maintain chilled products at or below 5°C Frozen products must remain frozen Food to be out of fridge/freezer for no more than 20 minutes Physical L L L Visual check and discard as appropriate Biological L L L Visual check and discard as appropriate Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 12 Sample Risk Analysis Chart — Preparation RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Ready to cook hazardous food HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Maintain temperature at or above 60°C or Follow the ‘2-hour/4-hour rule’ to limit time that food is between 5°C and 60°C Physical L L L Visual check and discard as appropriate Biological H M M Maintain temperature at or above 60°C or Follow the ‘2-hour/4-hour rule’ to limit time that food is between 5°C and 60°C Physical L L L Visual check and discard as appropriate Biological H H H Follow the ‘2-hour/4-hour rule’ to limit time that food is between 5°C and 60°C Physical L L L Visual check Biological H H H Use of pre-operational hygiene check sheet Physical L L L Visual check and discard as appropriate Non-hazardous foods — Biological L L L Visual check Dry stores, unfilled cakes and pastries Physical L L L Visual check and discard as appropriate Egg-based products Ready to serve fruit and vegetables eg salads Ready to cook fruit and vegetables Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 13 Key: H = High M = Medium L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 14 Sample Risk Analysis Chart — Cook RISK ASSESSMENT INPUT/CONTROL Ready to cook hazardous foods that will be held after cooking Ready to cook hazardous foods that will be served immediately Egg-based products Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Internal temperature of wet dishes and all poultry dishes must be above 75°C Whole roast meats and portioned meat cuts must have all surfaces well cooked Physical L L L Visual check and discard as appropriate Biological H M M Cook to temperature for optimum product Physical L L L Visual check and discard as appropriate Biological H H H Cook to temperature for optimum product Physical L L L Visual check and discard as appropriate Biological L L L Temperature should be at or above 60°C Chemical L L L Correct cooking equipment selected Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 15 Sample Risk Analysis Chart — Hot Hold RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Egg-based products Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Heat to 75°C and hold at 60°C or above Follow the ‘2-hour/4-hour rule’ to limit time that food is between 5°C and 60°C Physical L L L Visual check and discard as appropriate Biological H H H Maintain at temperature for optimum product and Follow the ‘2-hour/4-hour rule’ to limit time that food is between 5°C and 60°C Physical L L L Visual check and discard as appropriate Chemical L L L Correct cooking equipment selected Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 16 Sample Risk Analysis Chart — Serve Hot RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Non-hazardous foods Key: H = High M = Medium HAZARDS PREVENTATIVE MEASURE Severity Risk Significance Biological H H H Food to be served to consumer immediately Physical L L L Visual check and discard as appropriate Biological L L L Food to be served to consumer immediately Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 17 Sample Risk Analysis Chart — Cool RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous foods Non-hazardous foods Key: H = High M = Medium HAZARDS PREVENTATIVE MEASURE Severity Risk Significance Biological H H H Cool internal temperature of food from 60C to 21C within two hours and from 21C to 5°C or below within a further four hours or discard Physical L L L Visual check and discard as appropriate Biological L L L Cool internal temperature of food from 60C to 21C within two hours and from 21C to 5°C or below within a further four hours or discard Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 18 Sample Risk Analysis Chart — Reheat RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous foods Egg-based products Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H All foods to be reheated to internal temperature of 75°C Reheating to take place within two hours of being 5°C or discarded Chemical L L L Correct use of containers Physical L L L Visual check and discard as appropriate Follow cleaning procedures Biological H H H Reheat to temperature to maintain optimum product only if product has not been previously held between 5°C and 60°C for more than two hours Physical L L L Visual check and discard as appropriate Biological L L L Vegetables reheated to internal temperature of 75°C within two hours of being 5°C or discarded Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 19 Sample Risk Analysis Chart — Cold Hold RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous foods Ready to cook hazardous foods Non-hazardous foods Key: H = High M = Medium HAZARDS Biological PREVENTATIVE MEASURE Severity Risk Significance H H H Food to be held at or below 5°C Follow the ‘2-hour/4-hour rule’ to limit time that food is between 5°C and 60°C Physical L L L Visual check and discard as appropriate Biological H H H Food to be held at or below 5°C Physical L L L Visual check and discard as appropriate Biological L L L Food to be held at or below 5°C Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 20 Sample Risk Analysis Chart — Serve Cold RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous foods Non-hazardous foods Key: H = High M = Medium HAZARDS PREVENTATIVE MEASURE Severity Risk Significance Biological H H H Food to be served to consumer immediately Physical L L L Visual check and discard as appropriate Biological L L L Food to be served to consumer immediately Physical L L L Visual check and discard as appropriate L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 21 Sample Risk Analysis Chart — Dispatch RISK ASSESSMENT INPUT/CONTROL Ready to serve hazardous food Ready to cook hazardous food Ready to serve fruit and vegetables — Prepared fruit and vegetables HAZARDS PREVENTATIVE MEASURE Severity Risk Significance Biological H H H All foods to be packaged and dispatched at a temperature of 5°C or below Physical L L L Visual check and discard as appropriate Biological H H H All foods to be packaged and dispatched at a temperature of 5°C or below Physical L L L Visual check and discard as appropriate Biological H H H All foods to be packaged and dispatched at a temperature of 5°C or below Physical L L L Visual check and discard as appropriate Biological L L L All foods to be packaged Physical L L L Visual check and discard as appropriate Cooked fruit and vegetables Non-hazardous foods — Dry stores, unfilled cakes and pastries Whole fruits and vegetables Key: H = High M = Medium L = Low Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 22 Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 23 HACCP audit tables HACCP audit tables are designed to indicate the monitoring required for each step of the food production process. The following sample audit tables have been included in this manual: Cook/Hold/Serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes Cook/Serve cook to order items: meat, fish, chicken, pasta, rice Cook/ /Hold/Serve eggs/egg-based products The model HACCP audit tables use the following abbreviations: CCP = Critical Control Point A point in the food production process at which loss of control may result in an unacceptable health risk. This process must be monitored. CP = Control Point A point in the food production process at which control measures are advisable. However, loss of control may not lead to an unacceptable health risk. This process may be monitored. Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 24 Prepare–cook–hold–serve 1. Receipt 2a. Dry storage 2b. Cold storage 2c. Frozen storage 3. Defrost 4. Preparation 5. Cooking 8a. Hot hold 6. Cool 7. Reheat 8b. Cold hold 10. Dispatch 9. Serve Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 9. Serve 25 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 1.Receipt of chilled foods CONTROL MEASURES HAZARD Growth of food-poisoning organisms and food spoilage Temperature Use-by dates CRITICAL LIMIT CCP Signs of deterioration Chilled food 5C or below What: chilled food item Reject if above 5C Frozen food must be frozen How: thermometer and visual checks Acceptable use-by date Where: surface of the food Reject frozen food that is not frozen No signs of spoilage When: each delivery Reject stock that is spoilt or has short useby date Notify supervisor Reject stock that is contaminated Notify supervisor Reject stock that is contaminated Notify supervisor Reject stock that is contaminated 1. Receipt of fruit and vegetables and dry goods Chemical Physical Chemical Appropriate transport of food Check for foreign objects and broken packaging Supplier Assurance Program CP CORRECTIVE ACTION MONITORING No indication of chemical contamination No broken packaging No foreign objects Who: staff member Nil contamination What: food items How: visual check Where: in boxes Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Notify supervisor RECORDS Goods Received Form Goods Received Form 26 Physical Check for foreign objects and broken packaging Nil contamination Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control When: each delivery Who: staff member Reject stock that is contaminated 27 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 2a. Dry storage and vegetable storage CONTROL MEASURES CCP Temperature CP Appropriate stock rotation and shelf life HAZARDS Growth of bacteria CRITICAL LIMIT 2b. Cool storage Physical and microbial contamination Growth of food-poisoning and foodspoilage bacteria Avoid crosscontamination Temperature Appropriate stock rotation and shelf life CCP Store fruit & vegetables at 4 – 10 (except tropical/potatoes and onions). Apply first-in-firstout procedure Separate fruit and vegetables from raw meat, fish and chicken Dry stores to be in sealed rigid containers Store at or below 5ºC Apply first-in-firstout procedure CORRECTIVE ACTION MONITORING What: food items Discard stock that is contaminated or past use-by date Discard contaminated food Move product to back up storage immediately Discard product that is outside temperature limits Adjust thermostat Check seals and loading Notify your supervisor How: thermometer and visual checks Storage Unit Temperatu re Log Where: refrigerator and dry store When: twice daily (refrigerator), weekly (dry store) Who: staff member What: chilled food How: thermometer and visual checks Where: refrigerator When: twice daily Who: staff member Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control RECORDS Storage Unit Temperatu re Log 28 Physical and microbial contamination Avoid crosscontamination Cover all food Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Discard contaminated food 29 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 2c. Freezer storage 3. Defrost CONTROL MEASURES CCP Temperature CCP Appropriate stock rotation and shelf life HAZARDS Growth of bacteria Physical and microbial contamination Avoid crosscontamination Growth of food-poisoning bacteria Temperature Physical and microbial contamination Avoid crosscontamination CP CRITICAL LIMIT Store at or below -18ºC Apply first-in-firstout procedure CORRECTIVE ACTION MONITORING What: frozen food Call maintenance How: thermometer and visual checks Discard thawed food that is outside temperature limits When: twice daily Adjust thermostat Who: staff member Check seals and loading Notify your supervisor Discard contaminated food Discard product that exceeds shelf life Where: freezer Cover all food Defrost as detailed in Work Instruction — Defrosting What: frozen food Where: refrigerator/ microwave oven Check equipment Cover food in fridge When: daily Discard contaminated food Notify supervisor Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control How: visual checks Who: staff member RECORDS Storage Unit Temperatu re Log Activity Log or Daily Diary 30 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 4. Preparation HAZARDS Growth of food-poisoning bacteria Physical and microbial contamination CONTROL MEASURES CCP Limit time for preparation of hazardous food CP CRITICAL LIMIT Follow ‘2-hour/4hour rule’ for ready-to-eat potentially hazardous foods Personal hygiene procedures Personal hygiene as per policy Vegetable preparation procedures Vegetable preparation as per policy CORRECTIVE ACTION MONITORING Chill food until required Where: kitchen Discard contaminated food When: during each shift Review procedures Discard contaminated food Review procedures What: time/food handler/area RECORDS Activity Log How: visual check Who: manager Chemical contamination Follow cleaning procedures Cleaning as per policy Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 31 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 5. Cooking CONTROL MEASURES HAZARDS Survival of food-poisoning organisms Time and temperature CCP CCP CRITICAL LIMIT Physical and microbial contamination Cleaning procedures Personal hygiene procedures Cook to 80ºC*. (All poultry & mince dishes and boned/rolled roasts and whole stuffed fish & dairy dishes) Whole roast meat and whole pieces of grilled meat and fish fillets: cook till outside is well browned/cooked Cleaning as per policy Personal hygiene as per policy MONITORING What: product How: thermometer/ visual CORRECTIVE ACTION Bring up to temperature Check equipment Discard contaminated food Review procedures RECORDS Activity Log or Daily Diary Where: core of product (temp) — poultry, mince, wet dishes, boned/rolled roasts and whole stuffed fish visual check of outside (whole roasts etc) utensils (cleaning) When: each batch Who: chef Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 32 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 6. Cooling HAZARDS 7. Reheating Growth of food-poisoning bacteria Physical and microbial contamination Growth of food-poisoning bacteria CONTROL MEASURES CCP Time and temperature CCP CRITICAL LIMIT Cool to 21ºC within two hours and from 21ºC to 5ºC within a further four hours Personal hygiene procedures Personal hygiene as per policy Cleaning procedures Cleaning as per policy Time and temperature CCP Heat to 75ºC within two hours of being 5ºC. CORRECTIVE ACTION MONITORING What: cooked food Discard products that have not cooled within critical limit Check equipment Notify your supervisor Discard contaminated food Review procedures Discard product that is not heated to 75ºC within two hours of being 5ºC Discard contaminated food Review procedures How: thermometer/visual check Where: temperature at core of product When: each batch Who: staff member What: Product How: thermometer/visual check RECORDS Activity Log or Daily Diary Activity Log or Daily Diary Where: core of product (temp) utensils (cleaning) Physical and microbial contamination Cleaning procedures Cleaning as per policy When: each batch Who: chef Personal hygiene procedures Personal hygiene as per policy Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 33 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 8. Holding HAZARDS Growth of food-poisoning bacteria CONTROL MEASURES CCP Temperature CCP CRITICAL LIMIT Hold at or above 60ºC (hot foods) Hold at or below 5C (cold foods) 9. Food service Physical and microbial contamination Food-poisoning organism contamination Physical contamination Personal hygiene Cleaning procedures Personal hygiene Follow ‘2-hour/4hour rule’ for potentially hazardous readyto-eat foods Hygiene as per policy CCP Cleaning procedures What: product How: thermometer/visual check Remove from service and reheat to 75ºC Remove from service and chill to 5C or below (cold foods) Check equipment Discard contaminated food Check procedures Discard contaminated food Check procedures Where: core of product (temp) Servery — personal hygiene and cleaning When: every 60 minutes Who: manager Cleaning as per policy Hygiene as per policy Cleaning as per policy CORRECTIVE ACTION MONITORING What: product How: visual check Servery — personal hygiene and cleaning When: before service RECORDS Time Log Preoperational Hygiene Check Sheet Cleaning Schedule Who: manager Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 34 Model HACCP Audit Table: Prepare–cook–hold–serve meat, fish, chicken, cooked rice, cooked pasta and dairy dishes OPERATION 10. Dispatch HAZARDS Growth of food-poisoning bacteria CONTROL MEASURES CCP Temperature CCP CRITICAL LIMIT 5C or below CORRECTIVE ACTION MONITORING What: time/food handler/area Do not dispatch food that is above 5C Discard contaminated food Do not dispatch unprotected food RECORDS Dispatch Check Sheet How: thermometer/visual check Food-poisoning organism contamination Personal hygiene procedures Personal hygiene as per policy Cleaning procedures Cleaning as per policy Where: kitchen When: at time of dispatch Physical contamination Visual checks Food contained in food grade packaging No physical contamination Food completely covered Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Who: staff member 35 Cook to order meat, fish, chicken, pasta, rice 1. Receipt 2a. Dry storage 2b. Cold storage 4. Preparation 5. Cooking 2c. Frozen storage 3. Defrost 9. Serve 9. Serve Food Safety Series 7 – Sample Food Safety Manual - Section 3 Process Control 36 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice OPERATION 1. Receipt of chilled foods CONTROL MEASURES CCP Temperature CCP Use-by dates Signs of deterioration HAZARD Growth of food-poisoning organisms and food spoilage CRITICAL LIMIT Chilled food 5C or below Frozen food must be frozen Acceptable use-by date No signs of spoilage CORRECTIVE ACTION MONITORING What: chilled food item Reject if above 5C Reject frozen food that is not frozen Reject stock that is spoilt or use-by date is too short Notify supervisor Reject stock that is contaminated Notify supervisor Reject stock that is contaminated Notify supervisor Reject stock that is contaminated Notify supervisor How: thermometer and visual checks Where: surface of the food When: each delivery 1. Receipt of fruit and vegetables and dry goods Chemical Physical Chemical Appropriate transport of food Check for foreign objects and broken packaging Supplier Assurance Program CP No indication of chemical contamination No broken packaging No foreign objects Nil contamination Who: staff member What: food items How: visual check Where: in boxes Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control RECORDS Goods Receiving Form Goods Receiving Form 37 Physical Check for foreign objects and broken packaging Nil contamination When: each delivery Reject stock that is contaminated Who: staff member Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 38 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice OPERATION 2a. Dry storage and vegetable storage CONTROL MEASURES CCP Temperature CP Appropriate stock rotation and shelf life HAZARDS Growth of bacteria CRITICAL LIMIT 2b. Cool storage Physical and microbial contamination Growth of food-poisoning and foodspoilage bacteria Avoid crosscontamination Temperature Appropriate stock rotation and shelf life CCP Store fruit & vegetables at 4 – 10 (except tropical/potatoes & onions) Apply first-in-firstout procedure Separate fruit and vegetables from raw meat, fish and chicken Dry stores to be in sealed rigid containers Store at or below 5ºC Apply first-in-firstout procedure MONITORING What: food items How: thermometer and visual checks RECORDS Discard stock that is contaminated or past use-by date Dry Store Check Sheet Where: refrigerator and dry store When: twice daily (refrigerator), weekly (dry store) What: chilled food Discard contaminated food Move product to back up storage immediately Discard product that is outside temperature limits. Adjust thermostat Check seals and loading Notify your supervisor How: thermometer and visual checks Where: refrigerator Who: staff member Storage Unit Temperatu re Log Who: staff member When: twice daily Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control CORRECTIVE ACTION Storage Unit Temperatu re Log 39 Physical and microbial contamination Avoid crosscontamination Cover all food Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Discard contaminated food 40 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice OPERATION 2c Freezer storage 3. Defrost CONTROL MEASURES CCP Temperature CCP Appropriate stock rotation and shelf life HAZARDS Growth of bacteria Physical and microbial contamination Avoid crosscontamination Growth of food-poisoning bacteria Temperature CP CORRECTIVE ACTION CRITICAL LIMIT MONITORING Store at below -18ºC What: frozen food Call maintenance Apply first-in-firstout procedure How: thermometer and visual checks Discard product that is outside temperature limits When: twice daily Adjust thermostat Who: staff member Check seals and loading Notify your supervisor Discard contaminated food Discard product that exceeds shelf life Check equipment Discard contaminated food Notify supervisor Cover all food Defrost as detailed in Work Instruction — Defrosting Where: refrigerator What: frozen food How: visual checks Where: refrigerator/ microwave oven RECORDS Storage Unit Temperatu re Log Activity Log or Daily Diary When: daily Physical and microbial contamination Avoid crosscontamination Cover food in fridge Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Who: staff member 41 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice OPERATION 4. Preparation HAZARDS 5. Cooking Growth of food-poisoning bacteria CONTROL MEASURES CCP Limit time for preparation of hazardous food CCP CRITICAL LIMIT Follow ‘2-hour/4hour rule’ for ready-to-eat potentially hazardous foods Physical and Microbial contamination Personal hygiene procedures Personal hygiene as per policy Vegetables preparation procedures Vegetable preparation as per policy Chemical contamination Follow cleaning procedures Cleaning as per policy Survival of food-poisoning organisms Physical and microbial contamination Time and temperature Cleaning procedures Personal hygiene procedures CP* Cook to recipe requirements Cleaning as per policy Personal hygiene as per policy CORRECTIVE ACTION MONITORING Chill food until required When: during each shift Discard contaminated food Who: manager Review procedures Discard contaminated food Review procedures What: product Bring up to temperature How: visual Check equipment What: time/food handler/area How: visual check RECORDS Activity Log or Daily Diary Where: kitchen Where: product (temp) utensils (cleaning) Discard contaminated food Review procedures Cleaning Schedule Activity Log or Daily Diary Cleaning Schedule When: each batch Who: chef Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 42 Model HACCP Audit Table: Cook to order meat, fish, chicken, pasta, rice 9. Serving Physical and microbial contamination Personal hygiene procedures Cleaning procedures CCP Personal hygiene as per policy What: food handler/area Cleaning as per policy How: visual check Where: kitchen Discard contaminated food Review procedures Preoperational Hygiene Check Sheet Cleaning Schedule When: at the start of each service time Who: manager * Operation 5 step is not a CCP because it is in the context of a cook to order kitchen, where there is no opportunity for monitoring during cooking. Steps 1–4 are the CCPs to minimise the possibility of contamination and growth of food-poisoning micro-organisms. The chefs will also have food safety training. Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 43 Egg-based products 1. Receipt 2. Storage 4. Preparation 5. Cooking 6. Cool 8a. Hot hold 8b. Cold hold 9. Serve 9. Serve Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 44 Model HACCP Audit Table: Cook–hold–serve — eggs/egg-based products OPERATION 1. Receipt of eggbased products HAZARDS Food-poisoning organisms and damaged eggs CONTROL MEASURES CCP Temperature CCP CRITICAL LIMIT Arrives at 5ºC or below Reject if above 5C Reject damaged eggs Notify supervisor Reject contaminated food Notify supervisor Reject damaged packaging Notify supervisor What: eggs and eggbased products Adjust thermostat Check seals and loading How: thermometer and visual checks Notify your supervisor Check equipment Discard contaminated food Notify your supervisor What: eggs and eggbased products How: thermometer and visual checks Chemical Appropriate transport of food No indication of chemical contamination CORRECTIVE ACTION MONITORING Where: surface of the food RECORDS Goods Receiving Form When: each delivery 2. Cool room storage Physical Food-poisoning bacterial growth Physical and microbial contamination Packaging intact Temperature Avoid crosscontamination CCP No broken packaging Store at 5ºC or below Who: staff member Where: refrigerator Cover all food When: twice daily Who: staff member Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Storage Unit Temperature Log 45 Model HACCP Audit Table: Cook–hold–serve — eggs/egg-based products OPERATION 4. Preparation HAZARDS Growth of food-poisoning bacteria CONTROL MEASURES CCP Preparation time not to exceed 90 minutes CCP CRITICAL LIMIT Follow ‘2-hour/4hour rule’ for ready-to-eat potentially hazardous foods CORRECTIVE ACTION MONITORING What: time/food handler/area Refrigerate eggs and egg-based products until required RECORDS Activity Log or Daily Diary How: visual check Cleaning Schedule Where: kitchen Bacterial contamination Use of undamaged eggs Eggs to have no dirt or cracks Physical contamination Personal hygiene procedures Personal hygiene as per policy Chemical contamination Cleaning procedures Survival of food-poisoning organisms 5. Cooking Time and temperature CP* When: during each shift Discard contaminated food Review procedures Cleaning as per policy Who: manager Cook according to recipe What: eggs and eggbased products Bring up to temperature How: visual Check equipment Activity Log or Daily Diary Cleaning Schedule Where: product Physical and microbial contamination Personal hygiene procedures Personal hygiene as per policy Cleaning procedures Cleaning as per policy Discard contaminated food Review procedures When: each batch Who: chef Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 46 Model HACCP Audit Table: Cook–hold–serve — eggs/egg-based products OPERATION 6. Cooling 8. Holding CONTROL MEASURES HAZARDS Growth of food-poisoning bacteria Physical and microbial contamination Growth of food-poisoning bacteria Time and temperature CCP CCP Personal hygiene procedures Cleaning procedures Time and Temperature CCP CRITICAL LIMIT Personal hygiene as per policy Cleaning as per policy Hold at above 60ºC (hot foods) Hold at or below 5C (cold foods) Physical and microbial contamination Cool to 21ºC within two hours and from 21ºC to 5ºC within a further four hours Personal hygiene Cleaning procedures If product is held between 5C and 60C – maximum time is 90 minutes Hygiene as per policy MONITORING CORRECTIVE ACTION Discard products that have not cooled to 21ºC within two hours or from 21ºC to 5ºC within a further four hours Where: temperature at core of product Check equipment When: each batch Notify your supervisor Who: manager Discard contaminated food Review procedures What: egg product How: thermometer/visual check Remove from service and reheat to 75ºC for one minute (hot foods) Remove from service and chill to 5C or below (cold foods) Check equipment What: egg product How: thermometer/visual check Where: core of product (temp) Servery — personal hygiene and cleaning When: every 60 minutes Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control Activity Log or Daily Diary Cleaning Schedule Time Log Cleaning Schedule Discard after 90 minutes of being held 5C – 60C. Discard contaminated food Check procedures Who: manager Cleaning as per policy RECORDS 47 Model HACCP Audit Table: Cook–hold–serve — Eggs/egg-based products OPERATION 9. Serving CONTROL MEASURES CCP Personal hygiene procedures CCP Cleaning procedures HAZARDS Physical and microbial contamination CRITICAL LIMIT CORRECTIVE ACTION MONITORING Personal hygiene as per policy What: food handler/area Cleaning as per policy How: visual check Where: kitchen Discard contaminated food Review procedures RECORDS Preoperational Hygiene Check Sheet Cleaning Schedule When: at the start of each service time Who: manager * Step 5 is not a CCP because many egg products cannot be cooked to a high enough temperature to kill pathogens. Steps 1–3 are the CCPs to minimise the possibility of contamination and growth of food-poisoning micro-organisms. The chefs will also have food safety training. Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control 48 Food Safety Series 7 Toolbox – Sample Food Safety Manual - Section 3 Process Control