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 5C or below
Frozen to –18C
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
60C to 21C within two hours and from
21C 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
60C to 21C within two hours and from
21C 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 5C or
below
What: chilled food
item

Reject if above
5C

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
5C (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 5C 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

5C or below
CORRECTIVE
ACTION
MONITORING
What: time/food
handler/area

Do not dispatch
food that is
above 5C

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 5C 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
5C

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
5C

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
5C (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 5C and
60C – 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 5C 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 5C – 60C.

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