HACCP and Food Safety

1
HACCP and Food Safety

• Information for all SchoolFood Employees

Sept 2006
2
Table of Contents

• Introduction
• What is HACCP?
• Why use HACCP?
• Who is responsible for HAACP?
• When is HACCP used?
• How is HACCP learned?
• HACCP Principles
• Seven Steps of HACCP
• The SchoolFood HACCP Program
• Critical Control Points
• Serving Safe Food
• It Starts with You
• Basic Biology
• Types of Contaminants
• Microbes 101
• FAT-TOM
• Bacterial Growth
• Contamination and Foodborne Illness
• Overview

• Safe Employees
• Overview
• Uniform Review
• Handwashing
• Using Gloves
• Thermometer Use
• During Prep and Service
• Purchasing and Receiving Safe Food
• Headquarters' Role
• Receiving Guidelines
• Inspection of Items Received
• Storing Safe Food
• Overview
• First In, First Out (FIFO)
• Labeling and Dating
• Equipment Temperatures
• Expiration Dates
• Best If Used By Guidelines

3
Table of Contents

• Preparing Safe Food
• Overview
• Temperature Review
• Defrosting Safely
• Hot Food Issues
• Cold Food Issues
• Satellite Food Issues
• Cross Contamination
• Storing Prepared Food Safely
• Cleaning and Sanitizing
• Preparing Solution
• Red Bucket, Gray Bucket
• Clean As You Go
• Can Opener and Slicer

• Integrated Pest Management
• Overview
• Storeroom Issues
• Communication
• HACCP Reviews
• Overview
• HACCP Review Form
• HACCP and DoH Inspections

4
What is HACCP?
Introduction

• Proven method used to ensure the safety of the
  foods we serve
• Originally developed for NASA space flights
• Systematic approach that ensures food safety by
  looking at all processes as food flows through
  our kitchens
• Ordering
• Receiving
• Storage
• Preparation and Holding
• Service

5
Why use HACCP?
Introduction

• It works!Proven Industry Standard
• It is mandatedSchoolFood must have procedures in
  place to demonstrate how we maintain and verify
  food safety
• USDA Requirement
• New York State Education Dept Requirement
• New York City Department of Health

6
Who is Responsible for HACCP?
Introduction

• Every SchoolFood employee
• Each employee has an individual and team role
• Correct issues immediately and inform coworkers
• Seek guidance from the Manager and Cook-in-Charge

7
When is HACCP Used?
Introduction

• At all times in our operations
• HACCP follows the flow of food through our
  kitchens
• Receiving
• Storage
• Preparation
• Service
• Clean-up
• When developing new recipes and procedures
• HACCP principles guide development and
  implementation

8
How is HACCP learned?
Introduction

• Training
• Classroom Training
• Training Centers
• Application
• During 120-day Probation period
• HACCP Inspection reviews
• Feedback
• Ask questions

9
Big Things to Remember
Key Points

• Top three causes of food borne illness
• we control the risk
• Food Temperatures
• Calibrate thermometers daily
• Check food temperatures at preparation, holding,
  and serving
• Cross Contamination
• Defrost food properly
• Keep stations clean
• Use sanitizing solution between tasks
• Poor Personal Hygiene
• Wash Hands frequently
• Use gloves

10
Food Temperatures
Key Points

• Keep food out of the Danger Zone at every stage
  of Production

Protein Items Cooked to Internal Temperature of
165F
Protein Items Stored at proper temperatures
Protein Items Served at Internal Temperature
above 140F
Protein Items Held at Internal Temperature above
140F
Protein Items Cooled to Internal Temperature
below 40F within two hours
11
Seven Steps of HACCP
HACCP Principles

• Assess the Hazards
• Review Operations
• Identify Critical Control Points
• Where hazards can be prevented, eliminated, or
  reduced
• Set Standards
• Guidelines for all operations
• Monitor Critical Control Points
• Verify proper procedures are being followed
• Take Corrective Action
• Correct issues immediately
• Keep Records
• Temperature and Production Records
• Verify the System is Working
• HACCP Review Team to verify

12
The SchoolFood HACCP Program
HACCP Principles

• SchoolFood integrates HACCP procedures into our
  daily practices
• HACCP is built into our operations
• Training Manuals provide direction and additional
  information
• Be ready to implement new procedures
• Based on real-world experience
• Based on HACCP reviews
• Based on new items and recipes

13
Critical Control Points
HACCP Principles

• Points where there is a potential danger to food
• Develop and implement a procedure to minimize the
  risk
• CCP Hot Food must be held at above 140F
• Procedure
• Monitor food temperatures during holding time
• Thermometers calibrated for accurate readings

14
It Starts With You
Serving Safe Food

• Understanding how important Food Safety is
• Applying HACCP principles at work (and home)
• Helping coworkers understand
• Asking Questions
• Following HACCP procedures
• Wearing a clean uniform
• Taking action
• Working smart
• Keeping customers safe

15
Types of Contaminants
Basic Biology

• Bacteria Causes most cases of food borne illness
• Viruses Focus on personal hygiene
• Parasites Need a host to survive
• Fungi spoilage microorganism
• Some contaminants show their danger
• Molds
• Sour Milk
• Some contaminants hide their danger
• Salmonella
• Hepatitis A

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ContaminantsBacteria
Basic Biology

• Bacteria
• Living, single-celled organisms
• Reproduce rapidly under right conditions
• Can survive freezing
• Some cause spoilage
• Some cause disease
• Some create toxins

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ContaminantsViruses
Basic Biology

• Viruses
• Reproduce inside a living cell
• Do not reproduce in food
• Some survive cooking and freezing
• Transmission
• Person-to-Person
• People-to-Food
• People-to-Food contact surfaces
• Poor personal hygiene can contribute to the spread

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ContaminantsParasites
Basic Biology

• Parasites
• Need a host to survive
• Grow naturally in some foods
• Can be transmitted to humans
• May be killed by proper cooking or freezing

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ContaminantsFungi
Basic Biology

• Fungi
• Spoil Food and can cause illness
• Grow best in sweet, acidic foods with low water
  activity

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Microbes 101
Basic Biology

• Food Borne Illness may result from
• Infection
• Pathogens grow in the intestines of someone who
  has eaten contaminated food symptoms may take
  time to appear
• Intoxication
• Caused by eating food containing poisonous toxins
  that are not destroyed by cooking

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• FoodEnergy to multiply
• AcidityProper pH level
• Temperatureproper range for growth
• Timeto multiply
• OxygenSurvival
• Moisture
• How do we control or limit the food bacteria need
  to grow?

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• FoodEnergy to multiply
• Foods that contain Proteins represent the largest
  risk
• Meat
• Poultry
• Dairy Products
• Eggs
• How do we control or limit the food bacteria need
  to grow?

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• AcidityProper pH level
• Bacteria need a neutral pH to grow
• Between 4.6 and 7.5 pH
• Acidic foods usually inhibit growth
• How do we control or limit the food bacteria need
  to grow?

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• Temperatureproper range for growth
• 40F to 140F is the Danger Zone
• Refrigeration will slow growth but not eliminate
  it
• Keeping food out of the Danger Zone will inhibit
  growth but will not kill bacteria
• Only cooking to proper temperature will kill
  bacteria
• How do we control or limit the food bacteria need
  to grow?

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• Timeto multiply
• Growth starts slowly then expands rapidly
• Some bacteria can double in twenty minutes
• Four hours in the Danger Zone can produce lethal
  levels of bacteria
• How do we control or limit the food bacteria need
  to grow?

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• OxygenSurvival
• Aerobic requires oxygen to grow
• Some bacteria have different requirements
• Anaerobic no oxygen required
• Facultative can grow with or without oxygen
• How do we control or limit the food bacteria need
  to grow?

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FAT-TOM
Basic Biology

• Bacteria require the following to grow
• Moisture
• Bacteria grow well in moist foods
• Drier foodless growth
• How do we control or limit the food bacteria need
  to grow?

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Bacterial GrowthTime
Basic Biology

• How Bacteria Grow over time
• Multiplication
• Bacteria will grow as long as conditions are
  right

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Bacterial GrowthConditions
Basic Biology

• How Bacteria grow in good conditions
• Growth Chart
• Lag Phase stable and preparing for growth
• Log Phase rapid growth
• Stationary Phase rate of death and growth are
  the same
• Death Phase More bacteria dying than growing

Stationary
Log
Death
Number of Bacteria
Lag
Time
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Bacterial GrowthTemperatures
Basic Biology

• How Bacteria Grow at Different Temperatures

At 50F
At 95F
At 44F
Number of Salmonella Cells
At 42F
2
0
1
3
4
5
DAYS
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Contamination and Foodborne Illness
Contamination and Foodborne Illness

• Biological contamination
• Bacteria, parasites, viruses and fungi
• Chemical contamination
• Toxic metals, pesticides and chemicals
• Physical contamination
• Foreign matter, staples, metal shavings

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Contamination and Foodborne Illness
Contamination and Foodborne Illness

• Biological contamination
• Bacteria, parasites, viruses and fungi
• To reduce the risk
• Cook and hold foods at proper temperatures
• Limit the time food spends in the Danger Zone
• Practice proper handwashing and good personal
  hygiene

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Contamination and Foodborne Illness
Contamination and Foodborne Illness

• Chemical contamination
• Toxic metals, pesticides and chemicals
• To reduce the risk
• Store chemicals away from food storage
• Store foods in proper containers
• Read labels

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Contamination and Foodborne Illness
Contamination and Foodborne Illness

• Physical contamination
• Foreign matter, staples, metal shavings
• To reduce the risk
• Examine contents of cans and cases
• Check can opener for metal shavings, nicks in the
  blade
• Evaluate products during preparation
• Report Foreign Matter incidents to LIC
  Headquarters and Field Office

35
Standard Operating Procedures

• SOPs provide guidance on how to complete many
  tasks
• Review posted SOPs and follow correct procedures

36
Safe Employees
Safe Employees

• Safe food begins and ends with you
• SchoolFood employees are on the front line
• Work to provide safe food to your customers
• Apply what you learn to your daily tasks
• Adhere to SchoolFood practices and procedures
• Ask questions if you are unsure of the proper
  procedure

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Uniform Review
Safe Employees

• Follow SchoolFood procedures
• Wear a clean uniform daily
• No nail tips or polish
• Visible Jewelry
• Wedding Band with no stones
• Watch
• Safe shoes
• Restrain Hair
• Hairnet worn hairline-to-hairline
• SchoolFood Hat if all hair is restrained
• Hairnet and Hat to restrain hair

38
Handwashing
Safe Employees

• How
• Wet Hands using Hot water
• Apply Soap
• Lather and Wash for 20 seconds
• Rinse
• Dry with paper towels
• Wash Hands After
• Using restroom
• Touching your hair or face
• Eating or Smoking
• Completing a task and before using new gloves
• After touching any source of contamination

39
Using Gloves
Safe Employees

• Gloves protect the food, not the employee
• Use gloves to avoid bare-hand contact with food
  during preparation and production
• Wear gloves while serving food
• Change gloves
• When moving from task to task
• After touching your hair or face
• After touching any source of contamination
• Do not store gloves in pockets or apron

40
Thermometer Use
Safe Employees

• A Tool for Food Safety
• Test and calibrate thermometers daily
• Use slush mixture of ice and water
• Place thermometer in mixture
• Needle should read 32F
• Adjust if necessary
• Retest if dropped

41
During Prep and Service
Safe Employees

• Sanitizing Solution at all work stations
• Clean as You Go
• Clear, Clean, and sanitize work station between
  tasks
• Follow temperature guidelines when preparing
  temperature-sensitive foods
• Sandwiches
• Hot Foods
• Label and Date prep items and leftovers

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Purchasing and Receiving Safe Food
Purchasing and Receiving Safe Food

• SchoolFood Food Technology Department sets
  specifications for our products
• Working with manufacturers
• Manufacturers monitor their food safety practices
  during production
• Microbiological testing completed regularly
• Receiving procedures continue the focus on safe
  food

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Receiving Guidelines
Purchasing and Receiving Safe Food

• Apply Food Safety principles when receiving
  deliveries
• Check temperatures of items
• Frozen items must be received in a frozen state
• Wet boxes signal the product has been defrosted
• Ice crystals signal the product has been thawed
  and refrozen
• Look for expiration dates
• Return unsatisfactory products to vendor

44
Inspection of Items Received
Purchasing and Receiving Safe Food

• Milk Temperatures
• Production dates and expiration dates
• USDA stamps
• Open cases of fruits and vegetables
• Notify Manager or Cook-in-Charge if you have
  questions

45
Storing Safe Food
Storing Safe Food

• Store frozen and refrigerated products quickly
• Date all products before stocking shelves
• All food stored 6 above the floor on racks
• Labels facing out
• Monitor refrigerator and freezer temperatures
  daily
• Utilize Best If Used By Guidelines

46
FIFO
Storing Safe Food

• First In, First Out
• Rotate stock to utilize the oldest product first
• Label cases with delivery dates
• mm/dd/yy
• Use FIFO in all storage areas
• Freezers
• Refrigerators
• Storerooms
• Paper Storage

47
Labeling and Dating
Storing Safe Food

• Label cases with delivery date and production
  date
• Label individual cans if they are removed from
  the case
• Ask Manager or Cook-in-Charge for help with some
  production dates
• Julian Calendar
• Use dates to monitor FIFO
• Cover, Label, and Date all leftover products

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Equipment Temperatures
Storing Safe Food

• Monitor daily
• Freezers 0F - -10F
• Refrigerators 36F 40F
• Milk Chests 36F 40F
• Warmers To hold food above 140F
• Opening and closing doors will affect internal
  temperature
• Place equipment repair request if equipment is
  not working properly

49
Expiration Dates
Storing Safe Food

• Expiration Date on package
• Milk
• Fresh Juices
• DoD Produce
• Yogurt
• Cookies
• Soda
• Monitor these dates and take action
• Notify the Manager or Cook-in-Charge if a product
  is approaching the expiration date

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Best If Used By Guidelines
Storing Safe Food

• Use production date to calculate shelf life
• Periodic review of all products
• Utilize products that are nearing their
  expiration date
• Inform Manager and Cook-in-Charge
• Ask questions!

51
Preparing Safe Food
Preparing Safe Food

• Preparation is where our focus on safety pays
  off
• Temperature Control
• Monitor Internal Temperature
• Monitor Holding Temperature
• Temperature Abuse
• Food held in Danger Zone
• Failure to cook to internal temperature of 165F
• Failure to properly chill foods
• Preparing meals too far in advance

52
Temperature Review
Preparing Safe Food

• Cold Foods
• Served and held at 40F and below
• Hot Foods
• Cooked to an internal temperature of at least
  165F
• Served and held at 140F and above
• Hot Foods cooled quickly for storage
• Two hour window to safe temperatures
• Wrap, label, date, refrigerate

Cold Food Hold and Serve at 40F and below
Cook to this temperature 165F
Hot Food Hold and Serve at 140and above
53
Defrosting Safely
Preparing Safe Food

• Defrost raw products on bottom shelf of
  refrigerator
• Prevent cross contamination
• Wash utensils and equipment between tasks
• Standardized recipes provide item-specific
  instructions
• Holding temperatures
• Holding times

54
Standardized Recipes

• Each recipe classified for Food Safety Purposes
• 1
• 2
• 3
• Follow HACCP and preparation instructions to
  maintain food safety

55
Hot Food Issues
Preparing Safe Food

• Always use Preheated ovens
• Batch Cook
• Monitor Cooking Temperatures
• Reheat once to over 165F if temperature falls
  below 140F
• Evaluate items for service the following day
• Wrap, Date, Refrigerate

56
Cold Food Issues
Preparing Safe Food

• Use Ice Packs and Cold Wells to maintain
  temperatures below 40F
• Monitor Temperatures during production
• Cold Wells and Salad Bars must have all spaces
  covered to be effective

57
Satellite Food Issues
Preparing Safe Food

• Satellite Meal Issues
• Temperature
• Verify temperatures before pick-up by courier
• Time
• Limit time between preparation and consumption
• Menu
• Certain items identified for Satellite use
• Quantity
• Check for proper production amounts

58
Cross Contamination
Preparing Safe Food

• Transfer of bacteria from one product to the
  other
• Prevent cross contamination
• Create barriers between food products
• Do not mix food from different batches
• Defrost raw meat on bottom shelf in refrigerator
• Use glovesno bare-hand contact with food
• Wash, Rinse, and Sanitize

59
Storing Prepared Food Safely
Preparing Safe Food

• Cool product as quickly as possible
• Transfer to shallow pans
• Place in refrigerator
• Place in Freezer
• On Ice Packs
• In Ice Water bath
• Stir contents frequently
• Monitor temperatures
• Drop to 70F within 2 hours
• Drop to 40F within an additional 4 hours
• Wrap, Date, and Label
• Do not crowd refrigerator
• Evaluate the following day for service
• Reheat to over 165F only once

60
Cleaning and Sanitizing
Cleaning and Sanitizing

• Bleach Solution
• 1 cap bleach to 1 gallon cool water
• Bleach is killed by hot water
• Immerse for at least one minute
• Allow to air dry
• Use paper towel to dry if needed
• Change solution after 2 hours or if it becomes
  cloudy
• Quaternary Solution
• 1 QuixPlus Towel in 1 gallon cool water
• Change solution after 2 hours or if it becomes
  cloudy

61
Cleaning and Sanitizing
Cleaning and Sanitizing

• Buckets
• Red Buckets for Sanitizing Solution
• Wash, Rinse, and Sanitize daily
• Grey Bucket
• Half Soapy Hot Water for Washing
• Half Hot Water for Rinsing

62
Clean As You Go
Cleaning and Sanitizing

• CAYGO
• Keep your station clear as you work
• Wash, Rinse, Sanitize between tasks
• Prevent work from piling up
• Work Clean
• Better Organization

63
Can Opener and Slicer
Cleaning and Sanitizing

• Breeding ground for bacteria
• Wash, Rinse, and Sanitize between each use
• Small details have a big impact
• Question What could happen?

64
Integrated Pest Management
Integrated Pest Management

• Team approach to managing pest control
• SchoolFood Staff
• Custodian
• Pest Control Technician
• Safe, approved products used in all areas
• Kitchen staff maintains a clean, clear
  environment
• Notify custodian of issues needing repair
• Inform Pest Control Technician if activity has
  increased or changed

65
Storeroom Issues
Integrated Pest Management

• All items stored on shelves at least 6 off floor
  on racks
• Date and rotate all items
• Check expiration dates weekly
• Sweep and check for activity daily
• Change glue boards
• Inform Manager of increased activity or entry
  points

66
Communication
Integrated Pest Management

• Successful implementation requires open
  communication between all groups
• Each has their role to play in maintaining a safe
  environment
• SchoolFood
• Cleanliness and reporting
• Custodian
• Repairs
• Pest Control
• Service school regularly

67
HACCP Reviews
HACCP Reviews

• HACCP Team evaluates our operations
• Schools are scored on how they implement and
  demonstrate safe food handling practices
• Strive for improvement and increased safety
• Discuss issues and develop safe work habits

68
HACCP Review Form
HACCP Reviews

• Review categories and subject
• Flow of Food followed through the operation
• Critical Control Points
• Proper procedures in place
• All employees engaged in the process
• Reinforcement and communication to resolve issues

69
HACCP Review and DoH Inspections
HACCP Reviews

• Each follow the same flow of food
• Use HACCP as a benchmark
• Schools with positive HACCP reviews will do well
  on DoH inspections
• How are we doing?
• DoH data posted for each school
• Parent review
• Principal review

70
What Happens Next

• Look for HACCP procedures during your training
  period
• Apply HACCP principles daily
• Ask questions and seek guidance from your Manager
  and Cook-in-Charge
• Be ready to accept change as HACCP procedures are
  updated to react to operational issues
• Be a team player! Positive HACCP and Department
  of Health results show effective teamwork

71
Group Task

• Review the scenario presented to your group
• Each group has fifteen minutes to discuss the
  scenario
• One person from each group will review their
  scenario with the entire group

72
Scenario 1
Group Discussion

• Think About This
• PS 234 is serving Fried Rice for lunch. The rice
  was properly cooked the day before at 10am. The
  covered rice was placed on the countertop and
  allowed to cool to room temperature. At 3pm the
  cook placed it in the refrigerator. At 9am the
  next day the cook combined the rice with the
  other ingredients and cooked the mixture to 165F
  for at least 15 seconds. The cook covered the
  rice and left it on the stove until she reheated
  it for service at 12noon. Within an hour of
  eating the rice, several children began vomiting,
  and a few had diarrhea. Samples from the children
  revealed that the rice, not the other
  ingredients, was considered the cause of the
  outbreak.
• What Happened and Why?

73
Scenario 2
Group Discussion

• Think About This
• PS 152 receives 3 cases of Teriyaki Chicken
  Patties with their delivery. The patties are
  frozen at the time of delivery, but you notice a
  lot of ice crystals inside the box. The patties
  will be used to make teriyaki wraps the next day
  and they are placed in the refrigerator (at 38F)
  until needed for preparation. The SchoolFood
  staff follows all proper preparation, cooking,
  holding, and serving procedures. Unfortunately,
  several children report cramps and pain and each
  one of them had eaten the teriyaki wrap.
• Explain why this may have happened

74
Scenario 3
Group Discussion

• Think About This
• Ed was instructed by the Cook-in-Charge to take
  out three boxes of raw chicken to defrost in the
  reach-in refrigerator. Ed placed the boxes above
  the bottom shelf because the pies for the
  Teachers Dining room were on the bottom shelf.
• What should Ed have done differently?