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pdfManaging Food Safety:
A Manual for the
Voluntary Use of
HACCP Principles for
Operators of Food
Service and Retail
Establishments
Additional copies are available from:
Office of Compliance
Division of Cooperative Programs (HFS-625)
Center for Food Safety and Applied Nutrition
Food and Drug Administration
5100 Paint Branch Parkway
College Park, MD 20740
(Tel) 301-436-2350
U.S. Department of Health and Human Services
Food and Drug Administration
Center for Food Safety and Applied Nutrition
[April 2006]
OMB Control No. 0910-0578
Expiration Date: 03/31/2009
See additional PRA statement in Annex 5 of this manual
Managing Food Safety: A Manual for the Voluntary Use of HACCP
Principles for Operators of Food Service and Retail Establishments
CHAPTER 1
INTRODUCTION............................................................................... 1
PURPOSE AND SCOPE................................................................................................. 1
Who has the responsibility for ensuring safe food? .................................................... 1
What is my health inspector's role in helping me to prevent foodborne illness in my
establishment? ...................................................................................................... 2
How can this manual help me to prevent foodborne illness? ..................................... 2
How was this manual prepared? ................................................................................ 3
Who regulates me? .................................................................................................... 3
Is it a requirement that I implement a food safety management system based on
HACCP principles?................................................................................................ 3
What do I need to assist me in using this manual? ................................................... 4
BACKGROUND .............................................................................................................. 5
What are the retail and food service industries? ........................................................ 5
What are food safety hazards? .................................................................................. 6
What are foodborne illness risk factors? .................................................................... 7
What is meant by active managerial control? ............................................................. 8
THE USE OF HACCP AS A FOOD SAFETY MANAGEMENT SYSTEM........................ 9
What are the seven HACCP principles?..................................................................... 9
How can HACCP principles be used in retail and food service operations?............. 11
SUMMARY.................................................................................................................... 11
CHAPTER 2
THE PROCESS APPROACH ......................................................... 13
APPLYING HACCP PRINCIPLES TO RETAIL AND FOOD SERVICE......................... 13
What is the process approach? ................................................................................ 13
What is the flow of food? .......................................................................................... 14
What are three food preparation processes most often used in retail and food service
establishments? .................................................................................................. 14
Process 1 - Food Preparation with No Cook Step .......................................... 14
Process 2 - Preparation for Same Day Service .............................................. 14
Process 3 - Complex Food Preparation ......................................................... 14
DANGER ZONE DIAGRAM .......................................................................................... 15
THE HAZARD ANALYSIS............................................................................................. 16
DETERMINING RISK FACTORS IN PROCESS FLOWS ............................................. 17
Facility-wide Considerations..................................................................................... 18
Food Preparation Process 1 - Food Preparation with No Cook Step ....................... 18
Food Preparation Process 2 - Preparation for Same Day Service ........................... 19
Food Preparation Process 3 - Complex Food Preparation....................................... 20
ii
CHAPTER 3
DEVELOPING YOUR FOOD SAFETY MANAGEMENT SYSTEM . 21
GETTING STARTED..................................................................................................... 21
What is food safety team?........................................................................................ 21
HOW TO USE THIS MANUAL. ..................................................................................... 22
PROCEDURAL STEP 1: Develop Prerequisite Programs .......................................... 24
Prerequisite Programs to Control Contamination of Food ........................................ 25
Prerequisite Programs to Control Bacterial Growth.................................................. 25
Prerequisite Programs to Maintain Equipment ......................................................... 26
PROCEDURAL STEP 2: Group Your Menu Items/Products......................................... 27
Table 1: Process-Specific Lists ................................................................................ 27
PROCEDURAL STEP 3: Conduct a Hazard Analysis ................................................... 28
PROCEDURAL STEP 4: Implement Control Measures in Prerequisite Programs or
at CCPs in Your HACCP Plans and Establish Critical Limits ................................... 31
Common Operational Steps Used in Retail and Food Service ............................ 32
Receiving........................................................................................................ 32
Storage........................................................................................................... 33
Preparation..................................................................................................... 35
Cooking .......................................................................................................... 36
Cooling ........................................................................................................... 37
Reheating ....................................................................................................... 38
Holding (Hot, Cold, or Time)........................................................................... 39
Set Up, Assembly, and Packing ..................................................................... 40
Serving/Selling ............................................................................................... 40
PROCEDURAL STEP 5: Establish Monitoring Procedures........................................... 41
PROCEDURAL STEP 6: Develop Corrective Actions ................................................... 42
PROCEDURAL STEP 7: Conduct Ongoing Verification................................................ 43
Frequency of Verification.......................................................................................... 44
Verification - Examples............................................................................................. 44
PROCEDURAL STEP 8: Keep Records ....................................................................... 46
Special Considerations Regarding Records............................................................. 48
PROCEDURAL STEP 9: Conduct Periodic Validation .................................................. 49
Validation Worksheet ............................................................................................... 50
CONCLUSION .............................................................................................................. 52
GLOSSARY .................................................................................................................. 53
ANNEX 1
RESOURCES AND REFERENCES .................................................... 59
Agencies .................................................................................................................. 59
Articles ..................................................................................................................... 62
Books ....................................................................................................................... 64
FDA Publications and Federal Regulations.............................................................. 65
ANNEX 2
SEAFOOD REFERENCES ................................................................ 67
iii
ANNEX 3
HAZARD ANALYSIS.......................................................................... 70
ANNEX 4
SAMPLE HACCP TABLES ................................................................ 76
ANNEX 5
PAPERWORK REDUCTION ACT OF 1995 ...................................... 82
iv
Chapter 1 – Introduction
PURPOSE AND SCOPE
"Foodborne illness in the United States is a major cause of personal distress,
preventable death, and avoidable economic burden. Mead et al. (1999)
estimated that foodborne diseases cause 76 million illnesses, 325,000
hospitalizations, and 5,000 deaths in the United States each year…The annual
cost of foodborne illness in terms of pain and suffering, reduced productivity, and
medical costs is estimated to be $10-83 billion.”
2001 Food Code
Public Health Service - Food & Drug Administration
U.S. Department of Health and Human Services
The statistics on foodborne illness speak for themselves. Regulatory officials and the
retail and food service industries they regulate must partner with each other if we are to
prevent or reduce foodborne illness. This Manual was prepared by the United States
Food and Drug Administration (FDA), in partnership with federal, state, and local
regulators, industry, academia, and consumers, to assist you, the operators of retail and
food service establishments, in your efforts to produce safe food.
Who has the responsibility for ensuring safe food?
“Delivering safe food to the dinner table is the
culmination of the work of many people.
Producers, shippers, processors, distributors,
handlers, and numerous others perform actions
every day that may affect the safety of our food.
Everyone's challenge is to perform these
individual actions as well as possible, so that the
food Americans eat is free from physical hazards
and dangerous levels of pathogenic
microorganisms and hazardous chemicals.”
2001 Food Safety Strategic Plan
GOAL 2 - RISK MANAGEMENT
The President’s Council on Food Safety
http://www.foodsafety.gov/~fsg/cstrpl-4.html#chap2
1
While every player in the flow of food from farm to table has some degree of
responsibility for food safety, you are usually the last line of defense before food
reaches the consumer. Because of this, you have a significant share of the
responsibility for ensuring safe food. By voluntarily developing a food safety
management system, you can better ensure that the foods served or sold in your
establishment are safe.
What is my health inspector’s role in helping me to prevent
foodborne illness in my establishment?
Regulatory food inspection programs provide you with feedback
on how well you are controlling certain conditions in your
establishment that can lead to foodborne illness. Although your
inspector can offer suggestions for how you can improve
conditions in your establishment, he or she cannot possibly
oversee every activity or function in your day-to-day operation.
Given this limitation, you clearly have the greatest impact on food
safety.
How can this manual help me to prevent foodborne illness?
“Voluntary approaches can complement regulatory programs, particularly where
government actions enhance existing incentives for individuals to adopt practices
that increase food safety. Other approaches rely on the power of information to
influence behavior. Such voluntary, prevention-oriented approaches will have a
greater chance of success if they are promoted in partnership with the affected
stakeholders”
2001 Food Safety Strategic Plan
The President’s Council on Food Safety
This Manual provides you with a “roadmap” for writing and voluntarily implementing a
food safety management system based on Hazard Analysis and Critical Control Point
(HACCP) principles. By voluntarily developing and implementing a food safety
management system like the one suggested in this Manual, you can take a proactive
role in ensuring that the food served or sold in your establishment is safe. Rather than
responding to a foodborne illness when it occurs, you can prevent it by taking active
steps to eliminate, prevent, or reduce to an acceptable level food safety hazards that
cause someone to be sick or injured.
2
If you already have an existing food safety management system, you may use the
concepts in this Manual to upgrade the system you have in place. Whether you are
developing a new food safety management system or merely upgrading the one you
currently have, this Manual encourages operators and regulators of retail and food
service to partner together to make the greatest impact on food safety.
How was this manual prepared?
The procedures and information presented in this manual were prepared with feedback
received from regional FDA food safety seminars and Food Safety Initiative grassroots
meetings. In addition, the Conference for Food Protection (CFP) has reviewed and
endorsed this manual and has provided FDA with comments and suggestions on two
separate occasions (in December 2001 and again in November 2002). Comments
received from these reviews were incorporated into this document by the FDA.
Who regulates me?
Although this document was written by FDA, your respective state, local, or tribal
government directly regulates your operation. Understand that the requirements of your
regulatory authority may not be the same as what is recommended in the model FDA
Food Code. The 2001 FDA Food Code is used as the basis of this document, but it is
neither federal law nor federal regulation. It also does not supercede the requirements
of your state, local, or tribal government. However, most states have adopted the Food
Code to regulate retail and food service establishments under their jurisdiction since it
represents FDA's best advice for a uniform system of regulation to ensure that food at
retail is safe and properly protected and presented. With this in mind, you should
compare the requirements of your state, local, or tribal government with any Food Code
requirements mentioned in this Manual to make sure they are consistent with one
another.
Is it a requirement that I implement a food safety
management system based on HACCP principles?
The Food Code clearly establishes that the implementation
of HACCP at retail should be a voluntary effort by industry.
If, however, you plan on conducting certain specialized
processes that carry considerably high risk, you should
consult your regulatory authority to see if you are required to
have a HACCP plan. Examples of specialized processes
covered in Chapter 3 of the Food Code include formulating
a food so that it is not potentially hazardous or using
performance standards to control food safety.
Federal performance standards define public food safety
3
2001
expectations for a product usually in terms of the number of disease-causing
microorganisms that need to be destroyed through a process. For example, instead of
cooking chicken to 165 ºF for 15 seconds as dictated in the Food Code, performance
standards allow you to use a different combination of time and temperature as long as
the same level of public safety is achieved. Use of performance standards allows you
to use innovative approaches in producing safe products.
When using performance standards or when conducting other specialized processes,
the FDA Food Code requires an establishment to obtain a variance, or exemption from
the requirements of the Code, and to implement a more comprehensive HACCP plan
than is outlined in this Manual. The regulatory authority must not only approve this
HACCP plan, but records generated in support of the plan must be made available for
review when requested.
Jurisdictions that have not adopted the Food Code, but otherwise allow the use of
performance standards or other specialized processing methods, may also require you
to obtain a variance. In such cases, the regulatory authority may also require that you
develop a more comprehensive HACCP plan than is outlined in this Manual. In some
jurisdictions around the country, the implementation of HACCP programs is a
requirement regardless of the processing methods used. You should consult your
regulatory authority if you are unsure of your requirements, if you plan on deviating from
the requirements, or if you plan on conducting specialized processes.
What do I need to assist me in using this manual?
This Manual should be used in consultation with your federal, state, local, or tribal
regulatory authority or other food safety professionals. Your regulatory authority can be
an important resource in the development of your food safety management system.
Regulatory food safety professionals can provide important information about the public
health rationale for controlling a particular food safety hazard.
It is recommended that you use the latest version of the FDA Food Code, if applicable,
or a copy of your local or state regulations as a reference. Many of the requirements in
the Food Code or your local or state regulations provide fundamental prerequisites to
implementing a food safety management system based on HACCP principles. If you do
not have a copy of the Food Code, you can refer to Annex 1 of this Manual for
information on how to obtain a copy. It is also available on the FDA/Center for Food
Safety and Applied Nutrition website at: http://www.cfsan.fda.gov/~dms/foodcode.html.
4
BACKGROUND
What are the retail and food service industries?
Unlike many food processing operations, the retail and food service industries are not
easily defined by specific commodities or conditions. These establishments share the
following characteristics:
•
These industries have a wide range of employee resources, from highly trained
executive chefs to entry-level front line employees. Employees may have a broad
range of education levels and communication skills. It may be difficult to conduct
in-house training and maintain a trained staff because employees may speak
different languages or there may be high employee turnover.
•
Many are start-up businesses operating without the benefit of a large corporate
support structure. Having a relatively low profit margin means they may have
less money to work with than other segments of the food industry.
•
There is an almost endless number of production techniques, products, menu
items, and ingredients used. Suppliers, ingredients, menu items, and
specifications may change frequently.
The following is a partial listing of the types of businesses that are usually considered
part of the retail and food service industries:
Back-country guided trips for groups
Bakeries
Bed and breakfast operations
Cafeterias
Camps - recreational, children’s, etc.
Casinos, bares, and taverns
Child and adult day care
Church kitchens
Commissaries
Community fund raisers
Convenience stores
Fairs
Food banks
Grocery stores with specialized departments
deli
in-store prepared foods
produce
meat and seafood
What are food safety hazards?
5
Health care facilities
Interstate conveyances
Markets
Meal services for home-bound persons
Mobile food carts
Penal institutions
Restaurants
chains
international specialties
fast food
full service
independent operations
road-side stands
schools
Snack bars
Temporary outdoor events
Vending machines
Hazards are biological, physical, or chemical properties that may cause food to be
unsafe for human consumption. The goal of a food safety management system is to
control certain factors that lead to out-of-control hazards.
Because many foods are agricultural products and have started their journey to your
door as animals and plants raised in the environment, they may contain microscopic
organisms. Some of these organisms are pathogens which means that under the right
conditions and in the right numbers, they can make someone who eats them sick. Raw
animal foods such as meat, poultry, fish, shellfish, and eggs often carry bacteria,
viruses, or parasites that can be harmful to humans.
Food can become contaminated by toxic chemicals or toxins in your establishment or in
the environment. Physical objects may also contaminate food and cause injury. Food
may become naturally contaminated from the soil in which it is grown or from harvest,
storage, or transportation practices. Some foods undergo further processing and at
times, despite best efforts, become contaminated. These inherent hazards, along with
the hazards that may be introduced in your establishment such as metal fragments from
grinding can lead to injury, illness, or death. Hazards are a huge threat to your
business. Think of hazards as ticking bombs in your establishment. Unless they are
kept under control, they could result in financial ruin for your business.
Hazards include –
Biological agents
• Bacteria and their toxins
• Parasites
• Viruses
Physical Objects
• Bandages
• Jewelry
• Stones
• Glass
• Bone and metal fragments
• Packaging materials
6
Chemical Contamination
• Natural plant and animal toxins
• Unlabeled allergens (allergen-causing protein)
• Nonfood-grade lubricants
• Cleaning compounds
• Food additives
• Insecticides
What are foodborne illness risk factors?
The Centers for Disease Control and Prevention (CDC) Surveillance Report for 19931997, “Surveillance for Foodborne-Disease Outbreaks – United States,” identifies the
most significant contributing factors to foodborne illness. Five of these broad categories
of contributing factors directly relate to food safety concerns within retail and food
service establishments and are collectively termed by the FDA as “foodborne illness risk
factors.” These five broad categories are:
•
•
•
•
•
Food from Unsafe Sources
Inadequate Cooking
Improper Holding Temperatures
Contaminated Equipment
Poor Personal Hygiene
No national baseline on the occurrence of foodborne illness risk factors was available
until 2000 when FDA released the Report of the FDA Retail Food Program Database of
Foodborne Illness Risk Factors. The report, commonly referred to as the “FDA Baseline
Report,” is provided to regulators and industry with the expectation that it will be used to
focus greater attention and increased resources on the control of foodborne illness risk
factors. A copy of the report is available from FDA through the following website:
http://www.cfsan.fda.gov/~dms/retrsk.html.
Based on the measurable trends identified in CDC’s 1993-1997 Surveillance Report and
in FDA’s Baseline Report, FDA recommends that your food safety management system
focus on establishing active managerial control of the five CDC-identified risk factors.
7
What is meant by active managerial control?
The term “active managerial control” is used extensively
throughout this document to describe your role for developing and
implementing a food safety management system to reduce the
occurrence of risk factors. Although the term “active managerial
control” may be new to some, the basic management principles
are probably already being used in your day-to-day operations.
Active managerial control means the purposeful incorporation of
specific actions or procedures by industry management into the
operation of your business to attain control over foodborne illness
risk factors. It embodies a preventive rather than reactive approach to food safety.
Having active managerial control includes having procedures in place for controlling
identified foodborne illness risk factors through a continuous system of monitoring and
verification.
FDA recognizes that there are many management systems that you can voluntarily
implement to achieve active managerial control of risk factors. This Manual focuses
only on the voluntary implementation of HACCP principles in your food safety
management system. Regardless of the system you use, effective elements of a food
safety management system may include –
•
•
•
•
•
•
•
•
•
•
•
Certified food protection managers who have shown a proficiency of required
information by passing a test that is part of an accredited program
Standard operating procedures (SOPs) for performing critical operational steps in
a food preparation process such as cooling
Recipe cards that contain the specific steps for preparing a food item and the
food safety critical limits such as final cooking temperatures that need to be
monitored and verified
Purchase specifications
Equipment and facility design and maintenance
Monitoring procedures
Record keeping
Employee health policy for restricting or excluding ill employees
Manager and employee training
On-going quality control and assurance
Specific goal-oriented plans, like Risk Control Plans (RCPs), that outline
procedures for controlling specific foodborne illness risk factors
8
THE USE OF HACCP AS A FOOD SAFETY MANAGEMENT SYSTEM
Since the 1960’s, food safety professionals have recognized the importance of HACCP
principles for controlling risk factors that directly contribute to foodborne illness. The
principles of HACCP embody the concept of active managerial control by encouraging
participation in a system that ensures foodborne illness risk factors are controlled.
HACCP is not a stand-alone program, but is built upon a foundation of operational
practices called prerequisite programs (discussed in Chapter 3). The success of a
HACCP program (or plan) is dependent upon both facilities and people. The facilities
and equipment should be designed to facilitate safe food preparation and handling
practices by employees. Furthermore, FDA recommends that managers and
employees be properly motivated and trained if a HACCP program is to successfully
reduce the occurrence of foodborne illness risk factors. Instilling food worker and
management commitment and dealing with problems like high employee turnover and
communication barriers should be considered when designing a food safety
management system based on HACCP principles.
Properly implemented, a food safety management system based on
HACCP principles may offer you the following other advantages:
•
•
•
•
•
•
Reduction in product loss
Increase in product quality
Better control of product inventory
Consistency in product preparation
Increase in profit
Increase in employee awareness and participation in food safety
What are the seven HACCP principles?
The 1997 National Advisory Committee for the Microbiological Criteria for Foods
(NACMCF) recommendations updated the seven HACCP principles to include the
following:
1.
Perform a Hazard Analysis. The first principle is about understanding the
operation and determining what food safety hazards are likely to occur. The
manager needs to understand how the people, equipment, methods, and foods
all affect each other. The processes and procedures used to prepare the food are
also considered. This usually involves defining the operational steps (receiving,
storage, preparation, cooking, etc.) that occur as food enters and moves through
the operation. Additionally, this step involves determining the control measures
that can be used to eliminate, prevent, or reduce food safety hazards. Control
measures include such activities as implementation of employee health policies
to restrict or exclude ill employees and proper handwashing.
9
2.
Decide on the Critical Control Points (CCPs). Once the control measures in
principle #1 are determined, it is necessary to identify which of the control
measures are absolutely essential to ensuring safe food. An operational step
where control can be applied and is essential for ensuring that a food safety
hazard is eliminated, prevented or reduced to an acceptable level is a critical
control point (CCP). When determining whether a certain step is a CCP, if there
is a later step that will prevent, reduce, or eliminate a hazard to an acceptable
level, then the former step is not a CCP. It is important to know that not all steps
are CCPs. Generally, there are only a few CCPs in each food preparation
process because CCPs involve only those steps that are absolutely essential to
food safety.
3.
Determine the Critical Limits. Each CCP must have boundaries that define
safety. Critical limits are the parameters that must be achieved to control a food
safety hazard. For example, when cooking pork chops, the Food Code sets the
critical limit at 145 ºF for 15 seconds. When critical limits are not met, the food
may not be safe. Critical limits are measurable and observable.
4.
Establish Procedures to Monitor CCPs. Once CCPs and critical limits have
been determined, someone needs to keep track of the CCPs as the food flows
through the operation. Monitoring involves making direct observations or
measurements to see that the CCPs are kept under control by adhering to the
established critical limits.
5.
Establish Corrective Actions. While monitoring CCPs, occasionally the
process or procedure will fail to meet the established critical limits. This step
establishes a plan for what happens when a critical limit has not been met at a
CCP. The operator decides what the actions will be, communicates those
actions to the employees, and trains them in making the right decisions. This
preventive approach is the heart of HACCP. Problems will arise, but you need to
find them and correct them before they cause illness or injury.
6.
Establish Verification Procedures. This principle is about making sure that the
system is scientifically-sound to effectively control the hazards. In addition, this
step ensures that the system is operating according to what is specified in the
plan. Designated individuals like the manager periodically make observations of
employees’ monitoring activities, calibrate equipment and temperature measuring
devices, review records/actions, and discuss procedures with the employees. All
of these activities are for the purpose of ensuring that the HACCP plan is
addressing the food safety concerns and, if not, checking to see if it needs to be
modified or improved.
10
7.
Establish a Record Keeping System. There are certain written records or
kinds of documentation that are needed in order to verify that the system is
working. These records will normally involve the HACCP plan itself and any
monitoring, corrective action, or calibration records produced in the operation of a
the HACCP system. Verification records may also be included. Records
maintained in a HACCP system serve to document that an ongoing, effective
system is in place. Record keeping should be as simple as possible in order to
make it more likely that employees will have the time to keep the records.
How can HACCP principles be used in retail and food service operations?
Within the retail and food service industries, the implementation of HACCP principles
varies as much as the products produced. The resources available to help you identify
and control risk factors common to your operation may also be limited. Due to this
diversity, implementation of “textbook” HACCP is impractical in most retail and food
service establishments.
Like many other quality assurance programs, the principles of HACCP provide a
common-sense approach to identifying and controlling risk factors. Consequently,
many food safety management systems at the retail level incorporate some, if not all, of
the principles of HACCP. While a complete HACCP system is ideal, many different
types of food safety management systems may be implemented to control risk factors.
It is also important to recognize that HACCP has no single correct application.
Variations in the procedures presented in this Manual are appropriate as long as they
are based on sound public health judgment. In addition to the material presented in the
text of this Manual, several references have been provided in Annex 1 to assist you in
developing a food safety management system specific to your operation.
SUMMARY
FDA endorses the voluntary implementation of food safety
management systems in retail and food service establishments.
Combined with good basic sanitation, a solid employee training
program, and other prerequisite programs, HACCP can provide
you and your employees a complete food safety management
system.
The goal in applying HACCP principles in retail and food service is to have you, the
operator, take purposeful actions to ensure safe food. You and your regulatory
authority have a common objective in mind – providing safe, quality food to consumers.
Your health inspector can help you achieve this common objective, but remember that
the ultimate responsibility for food safety at the retail level lies with you and your ability
to develop and maintain an effective food safety management system.
11
Managing food safety should be as fully integrated into your operation as those actions
that you might take to open in the morning, ensure a profit, or manage cash flow. By
putting in place an active, ongoing system, made up of actions intended to create the
desired outcome, you can achieve your goal of improving food safety. The application
of the HACCP principles provides one system that can help you accomplish that goal.
This Manual will provide details on how to organize your products so that you can
voluntarily develop your own food safety management system using HACCP principles.
The HACCP plans that you will develop using this Manual, in combination with
prerequisite programs (discussed in Chapter 3), will constitute a complete food safety
management system. Partnering with your regulatory authority or other food safety
professional is recommended, but the design, implementation, and success of your
system rests with you.
12
Chapter 2 - The Process Approach
APPLYING HACCP PRINCIPLES TO RETAIL AND FOOD SERVICE
What is the process approach?
Since the early 1980’s, retail and food service operators and regulators have been
exploring the use of HACCP in restaurants, grocery stores, and other retail food
establishments. Most of this exploration has centered on the question of how to stay
true to the definitions of HACCP yet still make the principles useful to an industry that
encompasses a very broad range of conditions. Through this exploration, HACCP
principles have been slightly modified to apply to the varied operations found at retail.
When conducting the hazard analysis, food manufacturers usually use food
commodities as an organizational tool and follow the flow of one product. This is a very
useful approach for producers or processors since they are usually handling one
product at a time. By contrast, in retail and
food service operations, foods of all types
are worked together to produce the final
product. This makes a different approach to
the hazard analysis necessary. Conducting
the hazard analysis by using the food
preparation processes common to a specific
operation is often more efficient and useful
for retail and food service operators. This is
called the "Process Approach" to HACCP.
The process approach can best be described
as dividing the many food flows in an
establishment into broad categories based
on activities or stages in the flow of food
through your establishment, then analyzing
the hazards, and placing managerial controls
on each grouping.
13
What is the flow of food?
The flow of food in a retail or food service establishment is the path that food follows
from receiving through service or sale to the consumer. Several activities or stages
make up the flow of food and are called operational steps. Examples of operational
steps include receiving, storing, preparing, cooking, cooling, reheating, holding,
assembling, packaging, serving, and selling. Keep in mind that the terminology used for
operational steps may differ between food service and retail food store operations.
What are the three food preparation processes most often used in retail and food
service establishments?
Most food items produced in a retail or food service establishment can be categorized
into one of three preparation processes based on the number of times the food passes
through the temperature danger zone between 41 ºF to 135 ºF:
• Process 1: Food Preparation with No Cook Step
Example flow: Receive – Store – Prepare – Hold – Serve
(other food flows are included in this process, but there is no cook step to destroy
pathogens)
• Process 2: Preparation for Same Day Service
Example flow: Receive – Store – Prepare – Cook – Hold – Serve
(other food flows are included in this process, but there is only one trip through
the temperature danger zone)
• Process 3: Complex Food Preparation
Example flow: Receive – Store – Prepare – Cook – Cool – Reheat – Hot
Hold – Serve
(other food flows are included in this process, but there are always two or more
complete trips through the temperature danger zone)
14
A summary of the three food preparation processes in terms of number of times through
the temperature danger zone can be depicted in a Danger Zone diagram. Note that
while foods produced using process 1 may enter the danger zone, they are neither
cooked to destroy pathogens, nor are they hot held. Foods that go through the danger
zone only once are classified as Same Day Service, while foods that go through more
than once are classified as Complex food preparation.
The three food preparation processes conducted in retail and food service
establishments are not intended to be all-inclusive. For instance, quick service facilities
may have “cook and serve” processes specific to their operation. These processes are
likely to be different from the “Same Day Service” preparation processes in full service
restaurants since many of their foods are generally cooked and hot held before service.
In addition, in retail food stores, operational steps such as packaging and assembly may
be included in all of the food preparation processes prior to being sold to the consumer.
It is also very common for a retail or food service operator to have a single menu item
(i.e. chicken salad sandwich) that is created by combining several components
produced using more than one kind of food preparation process. It is important for you
to remember that even though variations of the three food preparation process flows are
common, the control measures – actions or activities that can be used to prevent,
eliminate, or reduce food safety hazards – to be implemented in each process will
generally be the same based on the number of times the food goes through the
temperature danger zone.
15
THE HAZARD ANALYSIS
In the “process approach” to HACCP, conducting a hazard analysis on individual food
items is time and labor intensive and is generally unnecessary. Identifying and
controlling the hazards in each food preparation process listed above achieves the
same control of risk factors as preparing a HACCP plan for each individual product.
Example: An establishment has dozens of food items (including baked chicken and
meatloaf) in the “Preparation for Same Day Service” category. Each of the food items
may have unique hazards (See Annex 3, Table 1), but regardless of their individual
hazards, control via proper cooking and holding will generally ensure the safety of all of
the foods in this category. An illustration of this concept follows:
•
Even though they have unique hazards, baked chicken and meatloaf are items
frequently grouped in the “Same Day Service” category (Process 2).
•
Salmonella and Campylobacter, as well as spore-formers, such as Bacillus
cereus and Clostridium perfringens, are significant biological hazards in chicken.
•
Significant biological hazards in meatloaf include Salmonella, E. coli O157:H7,
Bacillus cereus, and Clostridium perfringens.
•
Despite their different hazards, the control measure used to kill pathogens in both
these products should be cooking to the proper temperature.
•
Additionally, if the products are held after cooking, then proper hot holding or
time control is also recommended to prevent the outgrowth of spore-formers that
are not destroyed by cooking.
As with product-specific HACCP, critical limits for cooking remain specific to each food
item in the process. In the scenario described above, the cooking step for chicken
requires a final internal temperature of 165 ºF for 15 seconds to control the pathogen
load for Salmonella. Meatloaf, on the other hand, is a ground beef product and requires
a final internal temperature of 155 ºF for 15 seconds to control the pathogen load for
both Salmonella and E. coli O157:H7. Note that there are some operational steps,
such as refrigerated storage or hot holding, that have critical limits that apply to all
foods.
16
The following table further illustrates this concept. Note that the only unique control
measure applies to the critical limit of the cooking step for each of the products. Other
food safety hazards and control measures may exist:
Process 2: Preparation for Same Day Service
Example Products
Meatloaf
Salmonella
Example Biological Hazards
E. coli O157:H7
Clostridium perfringens
Bacillus cereus
Various fecal-oral route
pathogens
Cooking at 155 °F for 15
Example Control Measures
(there may be others)
seconds
Refrigeration 41 °F or below
Hot Holding at 135 °F or above
OR Time Control for 4 hours or
less
No bare hand contact with RTE
food, proper handwashing,
exclusion/restriction of ill
employees
Chicken
Salmonella
Campylobacter
Clostridium perfringens
Bacillus cereus
Various fecal-oral route
pathogens
Cooking at 165 °F for 15
seconds
Refrigeration 41 °F or below
Hot Holding at 135 °F or above
OR Time Control for 4 hours or
less
No bare hand contact with RTE
food, proper handwashing,
exclusion/restriction of ill
employees
DETERMINING RISK FACTORS IN PROCESS FLOWS
Several of the most common risk factors associated with each food preparation process
are discussed below. Remember that while you should generally focus your food safety
management system on these risk factors, there may be other risk factors unique to
your operation or process that are not listed here. You should evaluate your operation
and the food preparation processes you use independently.
In developing your food safety management system, keep in mind that active
managerial control of risk factors common to each process can be achieved by either
designating certain operational steps as critical control points (CCPs) or by
implementing prerequisite programs. This will be explained in more detail in Chapter 3.
The HACCP plans that you will develop using this Manual, in combination with
prerequisite programs, will constitute a complete food safety management system.
17
Facility-wide Considerations
In order to have active managerial control over personal hygiene and crosscontamination, you must implement certain control measures in all phases of your
operation. All of the following control measures should be implemented regardless of
the food preparation process used:
•
•
•
•
No bare hand contact with ready-to-eat foods (or use of an approved,
alternative procedure) to help prevent the transfer of viruses, bacteria, or
parasites from hands
Proper handwashing to help prevent the transfer of viruses, bacteria, or
parasites from hands to food
Restriction or exclusion of ill employees to help prevent the transfer of
viruses, bacteria, or parasites from hands to food
Prevention of cross-contamination of ready-to-eat food or clean and sanitized
food-contact surfaces with soiled cutting boards, utensils, aprons, etc. or raw
animal foods
Food Preparation Process 1 – Food Preparation with No Cook Step
Example Flow: RECEIVE – STORE – PREPARE – HOLD – SERVE
Several food flows are represented by this particular process. Many of these food flows
are common to both retail food stores and food service facilities, while others only apply
to retail operations. Raw, ready-to-eat food like sashimi, raw oysters, and salads are
grouped in this category. Components of these foods are received raw and will not be
cooked prior to consumption.
Foods cooked at the processing level but that undergo no further cooking at the retail
level before being consumed are also represented in this category. Examples of these
kinds of foods are deli meats, cheeses, and other pasteurized products. In addition,
foods that are received and sold raw but are to be cooked by the consumer after
purchase, i.e. hamburger meat, chicken, and steaks, are also included in this category.
All the foods in this category lack a kill (cook) step while at the
retail or food service establishment. In other words, there is no
complete trip made through the danger zone for the purpose of
destroying pathogens. You can ensure that the food received
in your establishment is as safe as possible by requiring
purchase specifications. Without a kill step to destroy
pathogens, your primary responsibility will be to prevent further
contamination by ensuring that your employees follow good
hygienic practices.
18
Cross-contamination must be prevented by properly storing your products away from
raw animal foods and soiled equipment and utensils. Foodborne illness may result from
ready-to-eat food being held at unsafe temperatures for long periods of time due to the
outgrowth of bacteria.
In addition to the facility-wide considerations, a food safety management system
involving this food preparation process should focus on ensuring that you have active
managerial control over the following:
•
•
•
•
•
•
Cold holding or using time alone to inhibit bacterial growth and toxin
production
Food source (especially for shellfish due to concerns with viruses, natural
toxins, and Vibrio and for certain marine finfish intended for raw consumption due
to concerns with ciguatera toxin) (See Annex 2, Table 1)
Receiving temperatures (especially certain species of marine finfish due to
concerns with scombrotoxin) (See Annex 2, Table 2)
Date marking of ready-to-eat PHF held for more than 24 hours to control the
growth of Listeria monocytogenes
Freezing certain species of fish intended for raw consumption due to parasite
concerns (See Annex 2, Table 3)
Cooling from ambient temperature to prevent the outgrowth of spore-forming or
toxin-forming bacteria
Food Preparation Process 2 – Preparation for Same Day Service
Example Flow: RECEIVE – STORE – PREPARE – COOK – HOLD – SERVE
In this food preparation process, food passes through the danger zone only once in the
retail or food service establishment before it is served or sold to the consumer. Food is
usually cooked and held hot until served, i.e. fried chicken, but can also be cooked and
served immediately. In addition to the facility-wide considerations, a food safety
management system involving this food preparation process should focus on ensuring
that you have active managerial control over the following:
•
Cooking to destroy bacteria and parasites
•
Hot holding or using time alone to prevent the outgrowth of
spore-forming bacteria
Approved food source, proper receiving temperatures, and proper cold
holding prior to cooking are also important if dealing with certain marine
finfish due to concerns with ciguatera toxin and scombrotoxin. Consult
Annex 2 of this Manual for special considerations related to seafood.
19
Food Preparation Process 3 – Complex Food Preparation
Example Flow: RECEIVE – STORE – PREPARE – COOK – COOL – REHEAT – HOT
HOLD – SERVE
Foods prepared in large volumes or in advance for
next day service usually follow an extended
process flow. These foods pass through the
temperature danger zone more than one time;
thus, the potential for the growth of spore-forming
or toxigenic bacteria is greater in this process.
Failure to adequately control food product
temperatures is one of the most frequently
encountered risk factors contributing to foodborne
illness. In addition, foods in this category have the
potential to be recontaminated with L.
monocytogenes, which could grow during
refrigerated storage. FDA recommends that food handlers minimize the time foods are
at unsafe temperatures.
In addition to the facility-wide considerations, a food safety management system
involving this food preparation process should focus on ensuring that you have active
managerial control over the following:
•
Cooking to destroy bacteria and parasites
•
Cooling to prevent the outgrowth of spore-forming or toxin-forming bacteria
•
Hot and cold holding or using time alone to inhibit bacterial growth and toxin
formation
•
Date marking of ready-to-eat PHF held for more than 24 hours to control the
growth of Listeria monocytogenes
•
Reheating for hot holding, if applicable
Approved food source, proper receiving temperatures, and proper cold holding prior to
cooking are also important if dealing with certain marine finfish due to concerns with
ciguatera toxin and scombrotoxin. Consult Annex 2 of this Manual for special
considerations related to seafood.
20
Chapter 3 – Developing Your Food Safety System
GETTING STARTED
What is food safety team?
Use of this Manual is most effective when a team approach is used. The team should at
least have representation from all the areas of the operation that will be involved in the
implementation process. This includes, but is not limited to, the owner, the managers,
chefs, cooks, dishwashers, wait staff, and other individuals who might be actively
involved in the preparation and service of the food. Although managers are responsible
for designing the system, implementation involves the efforts and commitment of every
employee. Training managers and employees in their respective roles is crucial to the
success of your food safety management system. You may consider working with
outside consultants, industry trade associations, university extension services, and your
regulatory authority to ensure that your food safety management system is based on the
best available science and that it will control the identified hazards.
21
HOW TO USE THIS MANUAL
Just like a well-played chess game, building a food
safety management system takes time, patience, and
determination. Careful consideration must be given to
all aspects of your operation affecting food safety. To
assist you in building your food safety management
system, a series of procedural steps have been
developed to guide you through the process.
Each procedural step includes a short discussion. For
your convenience, you can use the tables provided in
Annex 4 of this Manual to capture your food safety
management system in writing. After you have read the
discussion under each procedural step, it is
recommended that you complete the tables in Annex 4
with the appropriate information for each food
preparation process conducted in your establishment.
For example, when you are finished developing your prerequisite programs in
Procedural Step 1, you may reference your prerequisite programs by title on the tables.
Upon completion of Procedural Step 2 (grouping your menu items/products into one of
the three processes), you may complete the menu item/product row on the tables for
each food preparation process. When you are finished identifying the hazards in
Procedural Step 3, you may fill in the appropriate columns. You may continue filling in
the tables through Procedural Step 9. When you are done, you will have up to 3 tables
containing all the information you need to implement your food safety management
system.
Two sets of tables have been provided for you to use in building
your system. You can use either set of these tables or you can
modify them to best suit your operation’s needs. The tables that are
provided will enable you to –
•
group menu items/products within your establishment into
one of three food preparation processes
•
conduct a hazard analysis on each process grouping and
identify control measures
•
decide how control measures will be managed (as CCPs in
HACCP plans or through prerequisite programs
•
identify the critical limits pertaining to the identified CCPs
22
•
develop monitoring procedures and corrective actions which are customized to fit
your operation
•
design the verification procedure needed
•
determine the type of record keeping you need to document you
are controlling significant food safety hazards
•
validate that the system can effectively control the food safety
hazards
The ideal progression of building a food safety management system according to this
manual is as follows:
Assemble Your HACCP Team
Procedural Step 1 (Develop Prerequisite Programs)
Procedural Step 2 (Group Menu Items/Products)
Procedural Step 3 (Conduct Hazard Analysis)
Procedural Step 4 (Implement Control Measures and Establish Critical
Limits)
Procedural Step 5 (Establish Monitoring Procedures)
Procedural Step 6 (Develop Corrective Actions)
Procedural Step 7 (Conduct Ongoing Verification)
Procedural Step 8 (Keep Records)
Procedural Step 9 (Conduct Periodic Validation)
23
PROCEDURAL STEP 1
Develop Prerequisite Programs
If you want to build a sturdy home, you should
start with a strong foundation. The same is
true of a food safety management system. In
order for your food safety management
system to be effective, you should first
develop and implement a strong foundation of
procedures that address the basic operational
and sanitation conditions within your
operation. These procedures are collectively
termed “prerequisite programs.”
When prerequisite programs are in place, you can focus more attention on the hazards
associated with the food and its preparation. Before beginning to write your food safety
management system, it is recommended that you develop and implement prerequisite
programs. Prerequisite programs may include such things as –
•
Vendor certification programs
•
Training programs
•
Allergen management
•
Buyer specifications
•
Recipe/process instructions
•
First-In-First-Out (FIFO) procedures
•
Other Standard Operating Procedures (SOPs)
Basic prerequisite programs should be in place to –
•
Protect products from contamination by biological, chemical, and physical food
safety hazards
•
Control bacterial growth that can result from temperature abuse
•
Maintain equipment
24
Prerequisite Programs to Control Contamination of Food
These procedures ensure that –
•
Soiled and unsanitized surfaces of equipment and utensils do not contact raw or
cooked (ready-to-eat) food
•
Workers with certain symptoms, such as vomiting or diarrhea, are
restricted or excluded
•
Raw animal foods do not contaminate cooked (ready-to-eat) food
•
Effective handwashing is practiced
•
Eating, smoking, and drinking in food preparation areas are prohibited
•
Water in contact with food and food-contact surfaces and used in the
manufacture of ice is potable
•
Toxic compounds are properly labeled, stored, and safely used
•
Contaminants such as condensate, lubricants, pesticides, cleaning
compounds, sanitizing agents, and additional toxic materials do not
contact food, food-packaging materials, and food-contact surfaces
•
Food, food-packaging materials, and food-contact surfaces are not
contaminated by physical hazards such as broken glass from light
fixtures, jewelry, etc.
•
An effective pest control system is in place
•
Hair restraints are used
•
Clean clothing is worn
•
The wearing of jewelry (other than a wedding ring) is prohibited
Prerequisite Programs to Control Bacterial Growth
These procedures ensure that all potentially hazardous food is received and stored at a
refrigerated temperature of 41 ºF or below. Note that the Food Code makes some
allowances for specific foods that may be received at higher temperatures.
Prerequisite Programs to Maintain Equipment
25
These procedures ensure that –
•
Food-contact surfaces, including utensils, are cleaned, sanitized, and maintained
in good condition
•
Temperature measuring devices (e.g., thermometer or temperature recording
device) are calibrated regularly
•
Cooking and hot holding equipment (grills, ovens, steam tables, conveyer
cookers, etc.) are routinely checked, calibrated, and operated to ensure correct
product temperature
•
Cold holding and cooling equipment (refrigerators, rapid chill units, freezers,
salad bars, etc.) are routinely checked, calibrated, and operated to ensure
correct product temperature
•
Warewashing equipment is operated according to manufacturer’s specifications
•
Toilet facilities are accessible to employees and maintained
The items addressed by this procedural step are the foundation by which your entire
food safety management system is based. The success of any food safety
management system is dependent on how well you control these basic sanitation issues
in your establishment.
With this in mind, consider how you can actively monitor the activities associated with
the prerequisite programs to ensure that they are being implemented properly. If you
decide to control certain items in your food safety management system through
prerequisite programs, monitoring of the programs is recommended. Just as monitoring
allows you to prevent, eliminate, or reduce hazards in your HACCP plans, monitoring
may also allow you an opportunity to detect weaknesses in your prerequisite programs.
If you see areas needing improvement, you should take corrective actions immediately.
26
PROCEDURAL STEP 2
Group Your Menu Items/Products
To begin grouping your menu items/products, you should
review how your menu items or products flow through your
operation. You should note whether they undergo a cook
step for same day service, receive additional cooling and
reheating following a cook step, or have no cook step
involved. You may refer to Chapter 2 for organizing your
menu items or products by Process 1, 2, and 3.
Looking at your menu or food list, you should place each
item into the appropriate food preparation process. You
may discover that more than one food preparation process
is conducted within your operation. You may also need to
consult the annexes of this Manual to identify menu items or
products that need special consideration.
TABLE 1:
PROCESS-SPECIFIC LISTS
Example menu items or products that belong to each of the three food preparation
processes can be found in the following table. Note that the same menu item can
appear in more than one category depending on how it is prepared:
PROCESS #1
Food Preparation with No
Cook Step
PROCESS #2
Food Preparation for Same Day
Service
PROCESS #3
Complex Food
Preparation
raw meat and seafood (to be
cooked by consumer)
salad greens
fish for raw consumption
fresh vegetables
oysters or clams served raw
tuna salad
Caesar salad dressing
Cole slaw
sliced sandwich meats
sliced cheese
chicken salad (made from
canned chicken)
fried chicken
broiled fish
fried oysters
hamburgers
soup du jour
hot vegetables
cooked eggs
soups
gravies
sauces
large roasts
chili
taco filling
egg rolls
chicken salad
(made from raw
chicken)
27
PROCEDURAL STEP 3
Conduct a Hazard Analysis
In developing a food safety management system, you should identify the food safety
hazards that exist in the flow of food in your operation from receiving to service or sale.
By identifying the food safety hazards present in your system, you should then be able
to determine the possible control measures that may be
implemented to achieve active managerial control of the
foodborne illness risk factors leading to out-of-control hazards.
Control measures are any actions or activities that can be used
to prevent, eliminate, or reduce an identified hazard.
While the hazard analysis in the process approach to HACCP is
probably less complicated than in traditional HACCP, this
section is not intended to provide all the information you will
need to conduct a hazard analysis of your products. For a
more in-depth discussion on the hazard analysis process,
including questions to ask yourself and a listing of foods,
associated hazards, and control measures in retail and food
service, you may consult Annex 3 of this Manual. It is also
recommended that you consult Annex 2 of this Manual if your establishment serves or
sells seafood. In addition, FDA strongly recommends that you consult your health
inspector or other food safety professional during this and all other phases of your food
safety management system development.
As described in Chapter 2, the specific food safety hazards for each of the products
within a particular food preparation process may be varied, but the recommended
control measures for each of the products in each process will generally be the same.
As you conduct the hazard analysis, you will most likely find that regardless of the
specific food safety hazards present in the products in any particular food preparation
process, the foods within each of the food preparation processes share common
categories of hazards. This is why the control measures you apply to the products in
each of the three food preparation processes will generally be the same. Because of
this, you may use general categories to designate the types of food safety hazards
present in your operation.
For example, in process 2 you may have baked chicken, fried fish, grilled hamburgers,
and baked meatloaf that are all cooked and hot held before service. While each of
these foods may have unique food safety hazards, they all share general categories of
hazards and therefore the control measures that you may implement are basically the
same. Vegetative bacteria are controlled through proper cooking, spore-forming or
toxin-forming bacteria are controlled through proper hot holding, and fecal-oral route
pathogens such as Shigella, Salmonellae, and viruses are controlled through good
28
hygienic practices such as proper handwashing, no bare hand contact with ready-to-eat
food, and implementation of employee health policies. In addition, pathogens resulting
from cross-contamination may be controlled by proper sanitization and storage
practices. Other hazard categories and control measures may exist in this example.
The categories listed below are not all-inclusive and there may be overlap between
them. You may use different terminology from what is outlined in this Manual. The
category names that you use are unimportant as long as you know what hazards are
present in your system. Examples of general hazard categories that you may use to fill
in your tables are as follows:
•
BIOLOGICAL
1. Vegetative bacteria (such as Salmonella, Campylobacter, E.coli, and Vibrio)
2. Spore-forming or toxin-forming bacteria (such as Bacillus cereus, Clostridium
perfringens, Clostridium botulinum, and Staphylococcus aureus)
3. Fecal-oral route pathogens (such as parasites, various bacteria, and viruses)
4. Viruses (such as Hepatitis A and Noroviruses)
5. Bacteria, parasites, or viruses from cross-contamination
[applies to the transfer of disease-causing microorganisms to ready-to-eat
food by hands, food-contact surfaces, sponges, cloth towels and utensils that
are contaminated with disease-causing microorganisms. Also applies to the
transfer of disease-causing microorganisms from raw animal foods with
higher cook temperatures (i.e. chicken) to raw animal foods of less or cooking
temperatures (i.e. pork)]
•
CHEMICAL
6. General chemical contamination (cleaning compounds, sanitizers, allergens,
etc.)
7. Scombroid toxin (histamine production in certain fish) (See Annex 2)
8. Ciguatera toxin (natural toxin in certain fish) (See Annex 2)
•
PHYSICAL
9. General physical hazards such as bone or metal fragments, bandages,
jewelry, etc.
29
Some questions to ask yourself as you evaluate the food safety hazards present in your
products include:
•
Are there any ingredients or menu items of special concern such as
those listed in Annex 2?
•
Is this a potentially hazardous food requiring specific temperature
controls?
•
How will it be served? Immediately? Held on a buffet?
•
Does this food have a history of being associated with illnesses?
•
Will this require a great deal of preparation, making preparation
time, employee health, and bare hand contact with ready-to-eat
food a special concern?
•
How will employees exhibiting symptoms such as diarrhea or
vomiting be handled?
•
Are you serving food to a population that is known to be highly susceptible to
foodborne illness (e.g., residents of health care facilities, persons in child or adult
day care facilities, etc.)?
If you already have a working knowledge of the hazards associated with products in
your establishment, you can fulfill the hazard analysis step by identifying the control
measures in the Food Code that are associated with each operational step in your food
preparation processes. You may consult Annex 3 of the FDA Food Code to help you in
understanding the public health rationale behind the control measures and critical limits.
In the next procedural step, you should determine which of the control measures
identified in your hazard analysis are essential to the food’s safety, i.e. cooking. You
may choose to implement control measures in your HACCP plans at CCPs or through
your prerequisite programs.
30
PROCEDURAL STEP 4
Implement Control Measures in Prerequisite Programs or at CCPs in Your HACCP
Plans and Establish Critical Limits
The objective of this procedural step is to implement control measures in your food
safety management system to prevent, eliminate, or reduce hazards to acceptable
levels. Once control measures have been identified in Procedural Step 3 – Hazard
Analysis, you should determine how you will achieve active managerial control. Control
may be achieved at Critical Control Points (CCPs) in your HACCP plans or through
prerequisite programs.
By definition, a CCP is an operational step at which control can be applied
and is essential to prevent or eliminate a hazard or reduce it to an
acceptable level. If an operational step is the last step at which control can
be applied to prevent or eliminate a hazard or reduce it to an acceptable
level, then you should consider controlling it as a CCP. If a step later in
the process will control the hazards of concern, that step, rather than the
one in question, will most likely be a CCP.
Depending on your operation, control measures may be effectively
implemented in your prerequisite programs. For instance, you may decide
that cold holding during storage is best controlled through prerequisite
programs rather than through your HACCP plans. It is important to
consider the flow of food as you make this determination.
The Food Code provides specific measurable criteria referred to as critical limits
designed to prevent, eliminate, or reduce hazards in foods. The critical limits are based
on the best available science and pertain to control measures applied within operational
steps. Common examples might be time/temperature standards and no bare hand
contact with ready-to-eat food.
You should make sure that you have established the appropriate critical limits to control
the identified hazards. It is recommended that you refer to the most recent version of
the Food Code or your state, local, or tribal regulations for help with determining the
appropriate critical limits for the identified control measures.
31
COMMON OPERATIONAL STEPS USED IN RETAIL AND FOOD
SERVICE
The following information about the common operational steps conducted at retail is
provided to assist in your decision-making as you move through the procedural steps
presented in this document. Common operational steps conducted at retail include, but
are not limited to, receiving, storing, preparing, cooking, cooling, reheating, hot and cold
holding, assembly/set-up/packing, serving, and selling.
RECEIVING
Receiving is an important operational step to food safety. At receiving, your main
concern is contamination from pathogens and the formation of harmful toxins.
Two recommended control measures of
importance during this operational step include –
•
Receiving the food at proper temperatures
and getting perishable food into cold
storage quickly
•
Obtaining food, ingredients, and packaging
materials from approved sources (suppliers
who are regulated and inspected by
appropriate regulatory authorities)
Ready-to-eat, potentially hazardous food is a special concern at receiving. Because
this food will not be cooked before service, pathogenic bacterial growth could be
considered a significant hazard during this step for refrigerated, ready-to-eat foods.
Having prerequisite programs in place to control product temperature is generally
adequate to control the hazards present at receiving of most of these products. Besides
checking the product temperature, you should check the appearance, odor, color, and
condition of the packaging.
Seafood, whether ready-to-eat or not, requires special attention during receiving.
Federal regulations require processors of seafood and seafood products for interstate
distribution to have a HACCP plan. These processors are the only approved sources
for seafood sold in interstate commerce; therefore, you may ask your interstate seafood
supplier for documentation that the firm has a HACCP plan in place. Processors of
seafood and seafood products that are sold or distributed only within a state may or
may not be required to have a HACCP plan, depending on the state, local, or tribal
regulations.
32
In order to destroy parasites in certain species of fish intended for raw consumption,
either you or the seafood processor should freeze the fish at a given time and
temperature. You should ask to see specifications on these species of fish to be sure
that they have been frozen to destroy the parasites.
Molluscan shellfish (oysters, clams, mussels, and scallops)
that are received raw in the shell or shucked should be
purchased from suppliers who are listed on the FDA Interstate
Certified Shellfish Shippers’ List or on a list maintained by your
state shellfish control authority. Shellfish received in the shell
should bear a tag (or a label for shucked shellfish) that states
the date and location of harvest, in addition to other specific
information.
Finfish harvested from certain areas may naturally contain a toxin called ciguatera.
Other finfish may develop a toxin after harvest if strict temperature control is not
maintained. This toxin is called scombrotoxin (histamine). For finfish, temperature
control and approved sources are important at receiving because cooking will not
eliminate these toxins. For more information on toxins and parasites in fish, you may
refer to Annex 2 of this Manual.
STORAGE
When food is in refrigerated storage, your food safety management system should
focus on –
•
Maintaining temperature control to limit the growth of pathogenic bacteria that
may be present in a ready-to-eat product
•
Storing food so that cross-contamination of ready-to-eat food with raw animal
foods is prevented
When determining the storage temperature and monitoring frequency
of products in cold storage, you may decide to set the temperature
lower than what is required by your local regulations. By setting the
temperature lower than what is required by your regulations, small
upward deviations in temperature that you detect through frequent
monitoring can be quickly corrected before bacteria begin to grow.
For example, if you are storing potentially hazardous, ready-to-eat
foods under refrigeration, you may decide to set a critical limit for the
refrigeration units to operate at 38 ºF. This provides a safety cushion
that allows you the opportunity to see a trend toward exceeding 41 ºF
and to intervene with appropriate corrective actions before bacteria
begin to grow to dangerous levels.
33
Monitoring procedures for ready-to-eat food ideally include internal product temperature
checks. You should assess whether it is realistic and practical for you to do this
depending on the volume of food you are storing.
You may choose to base your monitoring system on the air temperature of the
refrigerated equipment as a prerequisite program. How often you should monitor the air
temperature depends on –
•
Whether the air temperature of the refrigerator accurately reflects the
internal product temperature – (Remember, your food safety refrigeration
temperature must be based on the internal product temperature of the
food stored within a refrigeration unit, not the ambient air temperature)
•
The capacity and use of your refrigeration equipment
•
The volume and type of food products stored in your cold storage units
•
The prerequisite programs that support monitoring this process
•
Shift changes, volume of business, and other operational considerations
Special consideration should be given to the storage of scombroid toxin-forming fish
due to the potential formation of histamine. To control histamine formation in scombroid
toxin-forming fish, the critical limit temperature of 41 ºF should be managed either
through your HACCP plan as a CCP or through your prerequisite programs. Also, your
HACCP plan or prerequisite programs should ensure that reduced oxygen packaged
smoked fish is maintained at 38 ºF to prevent the outgrowth of Clostridium botulinum
Type E.
Separating raw foods from ready-to-eat products in your operation’s refrigeration and
storage facilities can control the potential for cross-contamination. When determining
how you will arrange foods in your storage units to prevent cross-contamination, you
should consider the flow of food. For example, if chicken and beef are stored side-byside on a shelf, consider whether or not employee practices will allow the raw chicken to
drip onto the beef. Also, you should consider storing ready-to-eat, potentially hazardous
food away from the door, in the coolest part of the walk-in cooler. These products will
not undergo any further kill step; thus, preventing the growth of spore-forming bacteria
is especially important for these products.
34
PREPARATION
Of all the operational steps, preparation has the greatest variety of
activities that should be controlled, monitored, and in some cases,
documented. It is impossible to include in this Manual a summary
that covers the diversity of menus, employee skills, and facility
designs that impact the preparation of food. The preparation step
may involve several processes, including thawing, mixing together
ingredients, cutting, chopping, slicing, or breading.
At the preparation step, prerequisite programs can be developed to control some
hazards and assist in the implementation of a food safety management system that
minimizes –
•
bacterial growth
•
contamination from employees and equipment
Small batch preparation is an important tool for controlling bacterial growth because
limiting the amount of food prepared minimizes the time the food is kept at a
temperature that allows for growth. Pre-planning the volume of food and the time
needed for preparation minimizes the time food is in the temperature danger zone at
this operational step.
When thawing frozen foods, maintaining proper product temperature and managing
time are the primary controls for minimizing bacterial growth. Procedures should be in
place to minimize the potential for microbial, chemical, and physical contamination
during thawing.
Use of pre-chilled ingredients to prepare a cold product such as tuna salad may assist
you in maintaining temperature control for this process.
Front-line employees will most likely have the greatest need to work with the food. A
well-designed and managed personal hygiene program that has been communicated to
all employees will minimize the potential for bacterial, parasitic, and viral contamination.
It is suggested that your program include instructions to your employees as to when and
how to wash their hands. It is also very important to identify and restrict or exclude ill
employees from working with food, especially if they have diarrhea, vomiting, fever, or
jaundice.
Special consideration should be given to eliminating bare hand contact in the
35
preparation of ready-to-eat foods. How will you accomplish controlling the hazards
presented by hand contact with ready-to-eat foods? Does the time of day, frequency,
or duration of the preparation step allow for easy monitoring? You should review your
operation to determine whether this operational step will be controlled as a CCP in your
HACCP plans or as a prerequisite program.
Procedures should be in place to prevent cross-contamination from utensils and
equipment. Designated areas or procedures that separate the preparation of raw foods
from ready-to-eat foods minimize the potential for bacterial contamination. Proper
cleaning and sanitizing of food-contact surfaces is recommended in this operational
step.
COOKING
This operational step only applies to foods listed in Processes #2 and #3. Cooking
foods of animal origin is the most effective operational step for reducing or eliminating
biological contamination. Cooking to proper temperatures for a specified time will kill
most harmful bacteria and parasites. Therefore, frequent monitoring of cooking
temperatures is highly recommended.
You should determine the best system to use for ensuring that the proper cooking
temperature and time are reached. Checking the internal product temperature is the
desirable monitoring method. However, when large volumes of food are cooked, a
temperature check of each individual item may not be practical. For instance, a quick
service operation may cook several hundred hamburgers during lunch. Since checking
the temperature of each hamburger will probably not be reasonable for you to do, you
should routinely verify that the specific process and cooking equipment are capable of
attaining a final internal product temperature at all locations in or on the cooking
equipment.
Once a specific process has been shown to work for you, the
frequency of record keeping (to be discussed in Procedural Step
7) may be reduced. In these instances, a record keeping
system should be established to provide scheduled product
temperature checks to ensure that the process is working.
Special consideration should be given to time and temperature
when cooking raw animal foods. In developing your HACCP plans
or prerequisite programs, it is important to understand that the
critical limits are product-specific during the cooking step. For
example, the safe cooking temperature/time for poultry is 165 ºF
for 15 seconds, while 155 ºF for 15 seconds is the safe cooking
temperature for ground beef.
To ensure adequate destruction of pathogens by heat, the cooking operational step
36
should be managed either as a CCP in your HACCP plans or as a prerequisite program
and be based upon the same level of safety established by the critical limits in the Food
Code. Consult the latest edition of the Food Code available on the FDA/CFSAN
website (http://www.cfsan.fda.gov/~dms/foodcode.html) or your local or state
regulations for further guidance.
COOLING
One of the most labor-intensive operational steps is rapidly cooling foods to control
bacterial growth. Improper cooling of potentially hazardous foods has been consistently
identified as one of the factors contributing to foodborne illness. Foods that have been
cooked and held at improper temperatures provide an excellent environment for the
growth of spore-forming bacteria. Recontamination of a cooked food item by poor
employee practices or cross-contamination from other food products, utensils, and
equipment is also a concern at this operational step.
Improperly cooling food can begin a snowball effect that
cannot be reversed. Even with proper reheating,
toxins released by toxin-producing bacteria after
cooking and improper cooling may not be destroyed to
levels safe enough for human consumption. Special
consideration should be given to large food items such as
roasts, turkeys, thick soups, stews, chili, and large containers
of rice or refried beans. These foods take a long time to cool
because of their mass and volume. If the hot food container is
tightly covered, the cooling rate will be further slowed. By reducing
the volume of the food in an individual container and leaving an
opening for heat to escape by keeping the cover loose, the rate of cooling
can be dramatically increased.
Commercial refrigeration equipment is designed to hold cold food at the proper
temperature, not cool large masses of food. Some alternatives for cooling foods
include:
•
Using rapid chill refrigeration equipment designed to cool the food to acceptable
temperatures quickly by using increased compressor capacity and high rates of
air circulation
•
Avoiding the need to cool large masses by preparing smaller batches closer to
periods of service
•
Stirring hot food while the food container is in an ice water bath
37
•
In soups or stews, redesigning your recipe so that you cook a
concentrated base and add enough cold water or ice to make up the
volume that you need
•
Prechilling ingredients used to make products such as chicken and tuna
salad
Whichever cooling method you choose, you should verify that the process works. A
record keeping system should be established to provide scheduled product temperature
checks to ensure the process is working. If a specific process has been shown to work
for you, the frequency of record keeping may be re-evaluated. To control biological
hazards, it is recommended that the cooling operational step be managed either as a
CCP in your HACCP plans or as a prerequisite program and be based upon the same
level of safety established by the critical limits in the Food Code.
REHEATING
This operational step applies only to those foods
that you listed in Process #3. If food is held at
improper temperatures for enough time, pathogens
have the opportunity to multiply to dangerous
numbers. Proper reheating provides an important
control for eliminating some of these organisms.
Remember that although proper reheating will kill
most organisms of concern, it will not eliminate
toxins such as those produced by Staphylococcus
aureus and Bacillus cereus or foodborne viruses.
Special consideration should be given to the time
and temperature in the reheating of cooked foods.
To control biological hazards, it is recommended
that reheating be managed either as a CCP in your
HACCP plans or as a prerequisite program and be
based upon the same level of safety established by
the critical limits in the Food Code.
38
HOLDING (HOT, COLD, OR TIME)
All three processes may involve the holding of foods, i.e. hot and cold holding or use of
time alone as public health control. When there is a cooking step to eliminate bacteria,
all but the spore-forming bacteria should be destroyed. If cooked food is not held at the
proper temperature or, absent temperature control, for the appropriate time, the rapid
growth of these spore-forming bacteria is a major concern.
When food is held, cooled, and reheated in a food establishment there is an increased
risk from contamination caused by personnel, equipment, procedures, or other factors.
Harmful bacteria that are introduced into a product that is not held at proper
temperature have the opportunity to multiply to large numbers in a short period of time.
Once again, management of personal hygiene and the prevention of crosscontamination impact the safety of the food at this operational step.
Keeping food products at 135 ºF or above during hot
holding and keeping food products at or below 41 ºF is
effective in preventing microbial growth. As an
alternative to temperature control, the Food Code details
actions when time alone is used as a control, including a
comprehensive monitoring and food marking system to
ensure food safety.
How often you monitor the temperature of foods during
hot holding determines what type of corrective action you
are able to take when 135 ºF is not met. If the critical
limit is not met, your options for corrective action may
include evaluating the time the food is out of temperature
to determine the likelihood of hazards, and based on that
evaluation, reheating or discarding the food. Your
frequency of monitoring during this operational step may
mean the difference between reheating the food to 165 ºF
or discarding it.
When determining the monitoring frequency of cold product temperatures, it is
recommended that the interval between temperature checks is established to ensure
that hazards are being controlled and time is allowed for an appropriate corrective
action. For example, if you are holding potentially hazardous ready-to-eat foods under
refrigeration, such as potato salad at a salad bar, you may decide to set a critical limit at
41 ºF or below. You may also want to set a target, or operating limit, less than 41 ºF in
order to provide a safety cushion that allows you the opportunity to see a trend toward
exceeding 41 ºF and to intervene with appropriate corrective actions.
39
To control biological hazards, it is recommended that hot or cold holding or use of time
alone as a public health control be managed either as a CCP in your HACCP plans or
as a prerequisite program and be based upon the same level of safety established by
the critical limits in the Food Code.
SET UP, ASSEMBLY, AND PACKING
Set up, assembly, and packing are operational steps used by some retail food
establishments, including caterers [e.g., restaurant-caterers, interstate conveyance
caterers, commissaries, grocery stores (for display cases), schools, nursing homes,
hospitals, or food delivery services].
Set up, assembly, and packing may involve wrapping food items,
assembling these items onto trays, and packing them into a
transportation carrier or display case. An example would be an
airline flight kitchen where food entrees are wrapped, assembled,
and placed into portable food carts that are taken to a final holding
cooler. Hospital kitchens would be another example where patient
trays are assembled and placed into carriers for transportation to
nursing stations. Food may be placed in bulk containers for
transportation to another site where it is served.
Your food safety management system should address the potential for bacterial
contamination and growth, bare hand contact with ready-to-eat foods, and proper
handwashing.
SERVING/SELLING
This is the final operational step before the food reaches the customer. When
employees work with food and food-contact surfaces, they can easily spread bacteria
parasites, and viruses. Managing personal hygiene is important to controlling these
hazards. It is recommended that a management program for employee personal
hygiene be implemented that addresses the following:
•
•
•
•
Procedures for proper handwashing
The appropriate use of gloves and dispensing utensils
Control of bare hand contact with ready-to-eat foods
Exclusion and restriction of ill employees
Specific procedures are recommended for customer self-service displays such as salad
bars and buffet lines to protect food from contamination. Special consideration should
be given to preventing cross-contamination from soiled utensils and equipment and
minimizing contamination from the customer.
40
PROCEDURAL STEP 5
Establish Monitoring Procedures
Monitoring is observing or measuring specific operational steps in the food process to
determine if your critical limits are being met. This activity is recommended to make
sure your critical control points are under control. Monitoring will identify when there is
a loss of control or a trend toward a loss of control so that corrective actions (discussed
in Procedural Step 6) can be taken.
Consideration should be given to determining answers to the following
questions:
•
What will you monitor?
•
How will you monitor?
•
When and how often will you monitor?
•
Who will be responsible for monitoring?
In your food safety management system, certain processes have been identified as
requiring active managerial control. What you are going to monitor depends on the
critical limits you have established. Final temperature and time measurements are very
important, and you should determine how you will effectively monitor the critical limits
for them.
Determining the appropriate means for monitoring is an important factor in developing
your food safety management system. If equipment is selected to monitor a specific
CCP, you should ensure that it is accurate and routinely calibrated to ensure critical
limits are met. The equipment you choose should also be appropriate for the monitoring
that is being done. For example, a thermocouple with a thin probe is the most
appropriate tool for measuring the final product temperature of thin hamburger patties.
When deciding how often you will monitor, you should ensure that the monitoring
interval will be reliable enough to ensure hazards are being controlled. Your procedure
for monitoring should be simple and easy to follow.
Individuals chosen to be responsible for a monitoring activity may be a manager, line
supervisor, or other reliable employee. FDA recommends that employees be given the
training and equipment necessary to properly perform the monitoring activities.
41
PROCEDURAL STEP 6
Develop Corrective Actions
You should decide what type of corrective action to take if a critical limit is not met by
asking yourself the following questions:
•
What measures do you expect employees to take to correct the
problem?
•
Do your employees understand the corrective action?
•
Can the corrective action be easily implemented?
•
Are different options needed for the appropriate corrective
actions depending on the process and monitoring frequency?
•
How will these corrective actions be documented and
communicated to management so the system can be modified to
prevent the problem from occurring again?
Whenever a critical limit is not met, a corrective action must be carried out immediately.
A corrective action may be simply continuing to heat food to the required temperature.
Other corrective actions may be more complicated, such as rejecting a shipment of raw
oysters that does not have the required tags or segregating and holding a product until
an evaluation is done.
In the event that a corrective action is taken, you should review and modify your food
safety management system, if necessary. Even with the best of systems, errors occur
during food storage and preparation. A food safety management system based on the
HACCP principles is designed to detect errors and correct them before a hazard occurs.
A benefit to both you and your regulator is the ability to show that immediate corrective
action was taken to ensure that no unsafe food was served or sold to the consumer. It
is important to communicate to management all corrective actions in writing or
electronically.
42
PROCEDURAL STEP 7
Conduct Ongoing Verification
Because HACCP is a system to maintain continuous control of food safety practices,
implementation of the system should to be verified. Verification is simply making sure
that you are performing the activities as described in your food safety management
system.
Routine monitoring should not be
confused with verification. Verification
is making sure that all the activities
carried out in the implementation of
your food safety management system
are being done properly and at the
required frequency. Monitoring is one
of the many activities that needs to be
verified. This is a vital step in
ensuring that you have established
active managerial control of identified
hazards.
Verification should be conducted by someone other than the person who is directly
responsible for performing the activities specified in the food safety management
system. That person might be a manager, supervisor, designated individual, food
safety professional, or even your health inspector. If involved in the verification process,
your inspector can offer suggestions for how you can strengthen your food safety
management system.
Verification activities are conducted frequently, such as daily, weekly, monthly, etc., and
may include –
•
Observing that person(s) are carrying out the critical procedures
correctly
•
Observing the person doing the monitoring and determining whether
monitoring is being done as planned
•
Reviewing the monitoring records to determine if they are completed
accurately and consistently
•
Determining whether the records show that the frequency of
monitoring stated in the plan is being followed
43
•
Ensuring that corrective action was taken when the person monitoring
found and recorded that the critical limit was not met
•
Confirming that all equipment, including equipment used for
monitoring, was operated, maintained and calibrated properly
Frequency of Verification
Verification should occur at a frequency that can ensure the food safety
management system is being followed continuously to –
• Prevent unsafe food from reaching the consumer
• Take corrective action without loss of product
• Confirm that prescribed personnel practices are followed
• Ensure that personnel have the tools for proper personal
hygiene and sanitary practices (e.g., handwashing facilities,
sanitizing equipment, cleaning supplies, temperature measuring
devices, etc.)
• Comply with the established control procedures
Verification - Examples
Listed below are four examples of verification procedures:
Receiving logs: The manager reviews temperature logs of refrigerated products
at various intervals, such as on a weekly basis, or even daily if –
•
•
Receiving a high volume
Products received include scombroid toxin-forming fish such as fresh tuna.
Cooling logs: The kitchen manager checks that the "cooling log'' is
maintained for leftover foods on a weekly basis. The kitchen manager
checks to see that the time the food is placed in the cooler, its initial
temperature, and measurements of the time and temperature as the food is
cooled are recorded and initialed on the log sheet.
Handwashing and no bare hand contact logs: Nightly, the closing manager
checks to see if the logs maintained at the handwashing sinks and
preparation areas are complete.
44
Cooking: The manager checks the
time/temperature monitoring records for
cooking nightly to see that the required
number of temperature measurements
were taken during each shift.
45
PROCEDURAL STEP 8
Keep Records
As the manager of your operation, you may have several duties to perform in addition to
making sure that the activities in your food safety management system are being
performed at the proper frequency and with the proper method. Documenting these
activities provides one mechanism for verifying that the activities were properly
completed.
While record keeping is voluntary in most retail and food service operations, maintaining
documentation of the activities in your food safety management system may be vital to
its success. Remember that by keeping records you are going above and beyond what
your regulations normally require. Records provide documentation that appropriate
corrective actions were taken when critical limits were not met. In the event your
establishment is implicated in a foodborne illness, documentation of activities related to
monitoring and corrective actions can provide proof that reasonable care was exercised
in the operation of your establishment. Records may also show that on-going
verification was conducted on the food safety management system. In many cases,
your records can serve a dual purpose of ensuring quality and food safety.
In order to develop the most effective record keeping system for your operation, you
should determine what documented information will assist you in managing the control
of food safety hazards. A record keeping system
can be simple and needs to be designed to meet
the needs of your individual establishment. You
do not necessarily need to develop new records to
document the actions in the system.
Some recorded information like shellfish tags
should already be part of your food safety
management system, and an additional record
may not be needed. Your record keeping system
may use existing paperwork such as delivery
invoices for documenting product temperature.
Many retail and food service establishments have
implemented comprehensive record keeping
systems without having to generate a mountain of
paperwork
46
Employees are an important source for developing simple and effective record keeping
procedures. You should ask employees how they are currently monitoring CCPs or
prerequisite programs and discuss with them the types of corrective actions they are
currently taking when a critical limit is not met. Managers are responsible for designing
the system, but effective day-to-day implementation involves every employee.
The simplest record keeping system that lends itself to integration into existing
operations is always best. A simple, yet effective, system is easier to use and
communicate to your employees.
Record keeping systems designed to document process rather than product information
may be more useful in a retail and food service establishment, especially if you
frequently change menu items or products. Accurately documenting processes like
cooking, cooling, and reheating provides a mechanism for ensuring that you have active
managerial control of risk factors.
There are at least 5 types of records that may be maintained to support your food safety
management system:
•
•
•
•
•
Records documenting the activities related to the prerequisite programs
Monitoring records
Corrective action records
Verification and validation records (discussed under Procedural Step 9)
Calibration records
Once a specific process has been shown to work for you, such as an ice bath method
for cooling certain foods, the frequency of record keeping may be modified. This
approach is extremely effective for labor-intensive processes related to –
•
Cooking large volumes of food where a temperature check of each
individual item is impractical
•
Implementing a verified process that will allow employees to complete the
procedure in a scheduled workday
•
Cooling foods or leftovers at the end of the business day
•
Maintaining cold holding temperatures of ready-to-eat, potentially
hazardous foods in walk-in refrigeration units
47
Special Considerations Regarding Records
You are encouraged to periodically obtain feedback from your regulatory authority
regarding how well your system is working. You can invite your regulatory authority to
review or verify your voluntarily-implemented food safety management system. This
allows them the opportunity to offer suggestions for problems that they find in the
operation of your system, including discrepancies with the monitoring and record
keeping procedures.
Remember that the maintenance of records is required in the Food Code only in a
limited number of cases. When your food safety management system is voluntary, their
review of your system is by invitation only and they can only document violations that
they observe as they would during routine inspections. Records generated in support of
a voluntary food safety management systems may not to be used to verify compliance
with your regulations unless the records are specifically required by your regulations.
An example of when records may be used to verify compliance with your regulations
would be the maintenance of shellstock tags. If there is a requirement in your
regulations that shellstock tags be maintained in chronological order for at least 90
days, a health inspector may verify this requirement using your records.
In contrast, if your health inspector finds documented cases of inadequately cooked or
hot held foods being sold to consumers, he or she cannot take regulatory action against
you based on the documentation. Documentation of hot holding and cooking, like most
processes in your regulations, is probably not required. The fact that you are keeping
records of these processes means that you are probably going above and beyond what
is required by your regulations. Of course, your health inspector may point out
discrepancies and offer recommendations to you in hopes of preventing the problems
from happening again.
Of course, if during the review of your system evidence is found that a product still in
circulation poses a serious health threat to the public, the health inspector may initiate
an appropriate regulatory investigation as dictated by your regulatory agency. If it is
known by your health inspector or you that a product still on the market poses a health
threat to consumers, both of you should play your respective roles to remove the
product immediately. This may involve voluntary recall of the suspected products.
48
PROCEDURAL STEP 9
Conduct Periodic Validation
Once your food safety management system is established, you should periodically
review it to determine whether the food safety hazards are controlled when the system
is implemented properly. In this Manual, this review is known as validation.
Changes in suppliers, products, or preparation procedures may
prompt a revalidation of your food safety management system. A
small change could result in a drastically different outcome from
what you expect.
You may benefit from both internal (quality assurance) and
external validations that may involve assistance from the
regulatory authority or other consultants.
Validation is conducted less frequently (e.g., yearly) than on-going
verification. It is a review or audit of the plan to determine if –
•
•
•
•
•
•
•
Any new product/processes/menu items have been added to the menu
Suppliers, customers, equipment, or facilities have changed
Prerequisite programs are current and implemented
Worksheets are still current
CCPs are still valid, or if new CCPs are needed
Critical limits are set realistically and are adequate to control the
hazard (e.g., the time needed to cook a turkey to meet the Food Code
internal temperature requirement)
Monitoring equipment has been calibrated as planned
Validation helps you to –
•
•
•
Improve the system and HACCP plan by identifying weaknesses
Eliminate unnecessary or ineffective controls
Determine if the HACCP plan needs to be modified or updated
You can use the Validation Worksheet that follows to assist with the validation
process.
49
Validation Worksheet
Name of person responsible for validation: _______________________________
Title: ________________________________________
Frequency at which the validation is done: _______________________________
Reason, other than frequency, for doing the validation: ________________________________________________________________________
Date of last validation: _______________________
The length of time this record is kept on file (i.e. # months or years): ______________
1.
(a) Has a new product, process, or menu item
been added since the last validation?
(b) Has the supplier, customer, equipment,
or facility changed since the last
validation?
No ___
Yes ___
Go to Question #1b
Yes ___
No ___
Go to question #2
2.
Are the existing worksheets
accurate and current?
No ___
Yes ___
Go to Question #3
Worksheet information updated: Date: _______
Name: __________________
3.
Are the identified hazards
accurate and current?
No ___
Yes ___
Go to Question #4
Hazard analysis updated:
Date: _______
Name: __________________
4.
Are the existing CCPs correctly
identified?
No ___
Yes ___
Go to Question #5
CCPs updated:
Date: _______
Name: __________________
50
5.
Are the existing critical limits
appropriate to control each hazard?
No
___
Yes ___
Go to Question #6
CLs updated:
Date: _______
Name: __________________
6.
Do the existing monitoring
procedures ensure that the
critical limits are met?
No ___
Yes ___
Go to Question #7
Monitoring procedures updated: Date: _______
Name: __________________
7.
Do existing corrective actions ensure
that no injurious food is served or
purchased?
No ___
Yes ___
Go to Question #8
Corrective Actions updated:
Date: _______
Name: __________________
8.
Do the existing on-going verification
procedures ensure that the food safety
system is adequate to control hazards
and is consistently followed?
No ___
Yes ___
Go to Question #9
On-going verification
procedures updated:
Date: _______
Name: __________________
Does the existing record keeping system
No ___
provide adequate documentation that the
Yes ___
critical limits are met and corrective actions Go to Question #10
are taken when needed?
Record keeping procedures
updated:
Date: _______
Name: __________________
Are the existing prerequisite programs
current?
Prerequisite Programs
updated:
Date: _______
Name: __________________
9.
10.
No ___
Yes ___
The validation procedure is now complete. The next validation is due ___________________.
The changes made to the food safety management system were conveyed to the line supervisor or front-line employees on ________________.
Completed by:
Name
____________________________________________________________
Title
____________________________________________________________
Date
____________________________________________________________
51
CONCLUSION
Whether you used this manual to build a new
food safety management system for your
operation or merely to enhance the one you
already have in place, congratulations! You
are taking proactive steps to improve the
safety of foods prepared and sold in your
establishment. Remember that if you have any
questions or concerns, you should consult your
regulatory authority or other food safety
professional. They will be happy to work with
you to accomplish our common goal of
delivering safe, quality food to consumers.
52
Glossary
The definitions cited in Chapter 1 of the latest edition of the FDA Food Code should be
used to supplement this Glossary. In some cases, this Glossary condenses those
definitions for the purposes of this particular document.
ACCEPTABLE LEVEL means the presence of a food safety hazard at levels low
enough not to cause an illness or injury.
APPROVED SOURCE means an acceptable supplier to the regulatory authority based
on a determination of conformity with principles, practices, and generally recognized
standards that protect public health.
ACTIVE MANAGERIAL CONTROL means the purposeful incorporation of specific
actions or procedures by industry management into the operation of their business to
attain control over foodborne illness risk factors.
BACTERIA means single-cell microorganisms without distinct nuclei or organized cell
structures.
CCP means Critical Control Point.
CONTAMINATION means the unintended presence in food of potentially harmful
substances, including microorganisms, chemicals, and physical objects.
CONTROL MEASURE means any action or activity that can be used to prevent,
eliminate or reduce an identified hazard. Control measures determined to be essential
for food safety are applied at critical control points in the flow of food.
CORRECTIVE ACTION means an activity that is taken by a person whenever a critical
limit is not met.
CRITICAL CONTROL POINT (CCP) means an operational step in a food preparation
process at which control can be applied and is essential to prevent or eliminate a
hazard or reduce it to an acceptable level.
CRITICAL LIMIT means one or more prescribed parameters that must be met to ensure
that a CCP effectively controls a hazard.
53
CROSS-CONTAMINATION means the transfer of harmful substances or diseasecausing microorganisms to food by hands, food-contact surfaces, sponges, cloth towels
and utensils that touch raw food, are not cleaned, and then touch ready-to-eat foods.
Cross-contamination can also occur when raw food touches or drips onto cooked or
ready-to-eat foods.
DEVIATION means the failure to meet a required critical limit for a critical control point.
DANGER ZONE means the temperature range between 5 ºC (41 ºF) and 57 ºC (135 ºF)
that favors the growth of pathogenic microorganisms.
EXCLUDE means to prevent a person from working as a food employee or entering a
food establishment except for those areas open to the general public.
FISH
means fresh or saltwater finfish, crustaceans and other forms of aquatic life
(including alligator, frog, aquatic turtle, jellyfish, sea cucumber, sea urchin and
the roe of such animals) other than birds or mammals, and all mollusks, if such
life is intended for human consumption; and
includes an edible human food product derived in whole or in part
from fish, including fish that have been processed in any manner.
FOOD means raw, cooked, or processed edible substance, ice, beverage, chewing
gum, or ingredient used or intended for use or for sale in whole or in part for human
consumption.
FOOD ESTABLISHMENT means an operation at the retail or food service level, i.e.,
that serves or offers food directly to the consumer and that, in some cases, includes a
production, storage, or distributing operation that supplies the direct-to-consumer
operation. Refer to Chapter 1, Defining Retail Food and Food Service Industries, for
examples.
FOOD PREPARATION PROCESS means a series of operational steps conducted to
produce a food ready to be consumed.
FOODBORNE ILLNESS means sickness resulting from the consumption of foods or
beverages contaminated with disease-causing microorganisms, chemicals, or other
harmful substances.
FOODBORNE OUTBREAK means the occurrence of two or more cases of a similar
illness resulting from the ingestion of a common food.
HACCP means Hazard Analysis and Critical Control Point.
54
HACCP PLAN means, for the purposes of this document, a written document that is
based on the principles of HACCP and describes the procedures to be followed to
ensure the control of a specific process or procedure.
HACCP SYSTEM means the result of implementing the HACCP principles in an
operation that has foundational comprehensive, prerequisite programs in place. A
HACCP system includes the HACCP plan and all prerequisite programs.
HAZARD means a biological, physical, or chemical property that may cause a food to
be unsafe for human consumption.
HAZARD ANALYSIS AND CRITICAL CONTROL POINT (HACCP) means a
prevention-based food safety system that identifies and monitors specific food safety
hazards that can adversely affect the safety of food products.
INTERNAL TEMPERATURE means the temperature of the internal portion of a food
product.
MEAT means the flesh of animals used as food including the dressed flesh of cattle,
swine, sheep, or goats and other edible animals, except fish, poultry, and wild game
animals.
MICROORGANISM means a form of life that can be seen only with a microscope;
including bacteria, viruses, yeast, and single-celled animals.
MOLLUSCAN SHELLFISH means any edible species of raw fresh or frozen oysters,
clams, mussels, and scallops or edible portions thereof, except when the scallop
product consists only of the shucked adductor muscle.
MONITORING means the act of observing and making measurements to help
determine if critical limits are being met and maintained.
NATIONAL SHELLFISH SANITATION PROGRAM (NSSP) means the voluntary
system by which regulatory authorities for shellfish harvesting waters and shellfish
processing and transportation and the shellfish industry implement specified controls to
ensure that raw and frozen shellfish are safe for human consumption.
NSSP means National Shellfish Sanitation Program.
OPERATIONAL STEP means an activity or stage in the flow of food through a food
establishment, such as receiving, storage, preparation, cooking, etc.
PARASITE means an organism that lives on or in another, usually larger, host organism
in a way that harms or is of no advantage to the host.
55
PATHOGEN means a microorganism (bacteria, parasites, viruses, or fungi) that causes
disease in humans.
PERSONAL HYGIENE means individual cleanliness and habits.
pH means the measure of the acidity of a product.
POTENTIALLY HAZARDOUS FOOD:
means a food that is natural or synthetic and that requires temperature control
because it is capable of supporting:
•
•
•
the rapid and progressive growth of infectious or toxigenic
microorganisms,
the growth and toxin production of Clostridium botulinum, or
in raw shell eggs, the growth of Salmonella Enteritidis; and
Includes foods of animal origin that are raw or heat-treated; foods of plant origin
that are heat-treated or consists of raw seed sprouts, cut melons, and garlic in oil
mixtures that are not acidified or otherwise modified at a processing plant in a way
that results in mixtures that do not support growth of pathogenic microorganisms as
described above.
PREREQUISITE PROGRAMS means procedures, including Standard Operating
Procedures (SOPs), that address basic operational and sanitation conditions in an
establishment.
PROCEDURAL STEP means an individual activity in applying this Manual to a food
establishment’s operations.
PROCESS APPROACH means a method of categorizing food operations into one of
three categories:
•
Process 1: Food preparation with no cook step wherein ready-to-eat
food is received, stored, prepared, held and served;
•
Process 2: Food preparation for same day service wherein food is
received, stored, prepared, cooked, held and served; or
•
Process 3: Complex food preparation wherein food is received, stored,
prepared, cooked, cooled, reheated, hot held, and served.
56
READY-TO-EAT (RTE) FOOD means:
•
•
•
•
•
•
•
•
•
raw animal foods that have been properly cooked;
fish intended for raw consumption that has been frozen to destroy parasites;
raw fruits and vegetables that are washed;
fruits and vegetables that are cooked for hot holding;
plant food for which further washing, cooking, or other processing is not
required for food safety, and from which rinds, peels, husks, or shells, if
naturally present, are removed;
substances derived from plants such as spices, seasonings, and sugar; a
bakery item such as bread, cakes, pies, fillings, or icing for which further
cooking is not required for food safety;
dry, fermented sausages, such as dry salami or pepperoni;
salt-cured meat and poultry products, such as prosciutto ham, country-cured
ham, and Parma ham; and
dried meat and poultry products, such as jerky or beef sticks; and low acid
foods that have been thermally processed and packaged in hermetically
sealed containers.
RECORD means a documentation of monitoring observations and verification activities.
REGULATORY AUTHORITY means a federal, state, local, or tribal enforcement body
or authorized representative having jurisdiction over the food establishment.
RESTRICT means to limit the activities of a food employee so that there is no risk of
transmitting a disease that is transmissible through food and the food employee does
not work with exposed food, clean equipment, utensils, linens, and unwrapped singleservice or single-use articles.
RISK FACTOR means one of the broad categories of contributing factors to foodborne
illness outbreaks, as identified in the Centers for Disease Control and Prevention (CDC)
Surveillance Report for 1993-1997, that directly relates to foodborne safety concerns
within retail and food service establishments. The factors are Food from Unsafe
Sources, Inadequate Cooking Temperatures, Improper Holding Temperatures,
Contaminated Equipment, and Poor Personal Hygiene.
SEVERITY means the seriousness of the effect(s) of a hazard.
SOP means Standard Operating Procedure.
SHELLFISH means bivalve molluscan shellfish.
SPORE means a very tough, dormant form of certain bacterial cells that is very resistant
to desiccation, heat, and a variety of chemical and radiation treatments that are
otherwise lethal to vegetative cells.
57
SPORE-FORMER means a bacterium capable of producing spores under adverse
conditions.
STANDARD OPERATING PROCEDURE (SOP) means a written method of controlling
a practice in accordance with predetermined specifications to obtain a desired outcome.
TEMPERATURE MEASURING DEVICE means a thermometer, thermocouple,
thermistor, or other device for measuring the temperature of food, air, or water.
TOXIGENIC MICROORGANISMS means pathogenic bacteria that cause foodborne
illness in humans due to the ingestion of poisonous toxins produced in food.
VALIDATION means that element of verification focused on collecting and evaluating
scientific and technical information to determine if the HACCP plan, when properly
implemented, will effectively control the hazards.
VEGETATIVE CELL means a bacterial cell which is capable of actively growing.
VERIFICATION means, for the purpose of this document, ensuring that monitoring and
other functions of a HACCP plan are being properly implemented.
VIRUS means a submicroscopic parasite consisting of nucleic acid (DNA or RNA)
surrounded by a protein coat, and sometimes also encased in a lipid and glycoprotein
envelope. Viruses are completely dependent on a living host cell to survive and multiply,
and therefore can not multiply in or on food.
WATER ACTIVITY (Aw) means the quotient of the water vapor pressure of the
substance, divided by the vapor pressure of pure water at the same temperature.
Generally speaking, it is the amount of water available in the product to allow bacteria to
live and grow.
58
Annex 1 - Resources and References
The following is a partial list of references and sources of information that may be
helpful in developing a food safety management system in your establishment. Many
other references that address specific foods are listed in the FDA Food Code, Annex 2.
This list is not intended to be all-inclusive or exclusive and the listing of a material that is
not published by the federal government does not imply or convey FDA endorsement of
that material.
AGENCIES
United States Food and Drug Administration
•
Center for Food Safety and Applied Nutrition, Retail Food Protection Team
U.S. Food and Drug Administration
FDA, HFS-627
5100 Paint Branch Parkway
College Park, MD 20740-3835
•
Center for Food Safety and Applied Nutrition, Office of Compliance
Dr. John E. Kvenberg, Deputy Director, OC
U.S. Food and Drug Administration
HFS-600
5100 Paint Branch Parkway
College Park, MD 20740-3835
•
Regional Field Offices (Regional Retail Food Specialists)
Northeast (Maine, New Hampshire, Massachusetts, Vermont, Rhode Island,
Connecticut, and New York):
158-15 Liberty Avenue, HFR-NE4
Jamaica, NY 11433-1034
(718) 662-5621
FAX (718) 662-5434
59
One Montvale Avenue, HFR-NE250
Stoneham, MA 02180-3542
(781) 596-7700
FAX (781) 596-7896
Central - Mid Atlantic (New Jersey, Delaware, District of
Columbia, Maryland, Pennsylvania, Virginia, West Virginia,
Kentucky, and Ohio):
101 West Broad Street
Suite 400
Falls Church, VA 22046
(703) 235-8440 ext. 502
Central – Mid West (Illinois, Indiana, Michigan, Minnesota, North
Dakota, South Dakota, and Wisconsin):
20 North Michigan Ave., Suite 50
HFR-MW15
Chicago, IL 60602-4811
(312) 353-9400
FAX (312) 886-1682
240 Hennepin Avenue
Minneapolis, MN 55401
(612) 334-4100 ext. 115
FAX (612) 334-4134
Southeast (Alabama, Florida, Georgia, Louisiana, Mississippi,
North Carolina, South Carolina, Puerto Rico, Tennessee, and
Virgin Islands):
60 – 8th Street, N.E.
HFR-SE13
Atlanta, GA 30309-3959
(404) 253-1200 ext. 1265, 1267, 1268, 1273
FAX (404) 253-1207
Southwest (Arkansas, Oklahoma, Texas, Colorado, New Mexico,
Wyoming, Utah, Missouri, Kansas, Iowa, and Nebraska):
4040 N. Central Expressway, Suite 900
HFR-SW16
Dallas, TX 75204
(214) 253-4948, 4947, 4945
FAX (214) 253-4960
11510 W. 8th Street, HFR-SW36
60
Lenexa, KS 66285-5905
(913) 752-2401 FAX (913) 752-2487
Building 20, Denver Federal Center
P.O. Box 25087
Denver, CO 80225-0087
(303) 236-3026
FAX (303) 236-3551
Pacific (Alaska, Arizona, American Samoa, California, Hawaii,
Guam, Nevada, Idaho, Oregon, Washington, and Montana):
Office of Regional Director - Pacific Region
Oakland Federal Bldg., HFR-PA16
1301 Clay Street, Suite 1180N
Oakland, CA 94612-5217
(510) 637-3960 ext. 27
FAX (510) 637-3976
51 West Third Street
Tempe, AZ 85281
(480) 829-7396 ext. 35
FAX (480) 829-7677
9780 SW Nimbus Avenue
Beaverton, OR 97008-7163
(503) 671-9711 ext. 16
(503) 671-9445
•
Division of Human Resource Development, State Training Team.
15000 Crabbs Branch Rd. HFC-60
Rockville, MD 20855
(301) 594-0959
FAX (301) 594-1966
61
United States Department of Agriculture
•
Food Safety and Inspection Service
Office of the Director
USDA FSIS PPID/HACCP
Room 6912, Suite 6900E
1099 - 14th Street, N.W.
Washington, DC 20250-3700
(202) 501-7319 FAX (202) 501-7639
ARTICLES
Bryan, Frank. “Hazard Analyses of Street Foods and
Considerations for Food Safety.” Dairy, Food and
Environmental Sanitation, February 1995, pp. 64-69.
Bryan, Frank. “HACCP: Present Status and Future in
Contribution to Food Safety.” Dairy, Food &
Environmental Sanitation, November 1994, pp. 650655.
Bryan, Frank. “Procedures for Local Health Agencies
to Institute a Hazard Analysis Critical Control Point
Program for Food Safety Assurance in Food Service
Operations.” Journal of Environmental Health,
March/April 1985, pp. 241-245.
Bryan, Frank. “Hazard Analysis of Food Service
Operation.” Food Technology, February 1981, pp.
78-87.
Bryan, Frank. “Hazard Analysis Critical Control Point
Approach: Epidemiologic Rationale and Application to
Food Service Operations.” Journal of Environmental
Health, August 1981, pp. 7-14.
Bryan, Frank. “Factors that Contribute to Outbreaks
of Foodborne Disease.” Journal of Food Protection,
October 1978, pp. 816-827.
Bryan, F.L. and Lyon, J.B. “Critical Control Points of
Hospital Food Service Operations. Journal of Food
Protection, 1984.
62
Briley and Klaus. “Using Risk Assessment as a
Method of Determining Inspection Frequency.” Dairy
and Food Sanitation, December 1985, pp. 468-474.
Centers for Disease Control and Prevention.
Surveillance for Foodborne Disease Outbreaks –
United States, 1993-1997. Morbidity Mortality Weekly Report.
#49 (SS01), USPHS, March 17, 2000, pp. 1-51.
Mead, P.S., Slutsker, L., Dietz, V., McCraig, L.F.,
Bresee, J.S., Shapiro, C., Griffin, P.M., Tauxe, R.V.
“Food-related Illness and Death in the United States.”
Emerg. Infect. Dis. Vol. 5, No. 5, 1999. in:
http://www.cdc.gov/ncidod/EID/vol5no5/mead.htm.
National Advisory Committee on Microbiological
Criteria for Food (NACMCF). 1997 Hazard Analysis
and Critical Control Point System, USDA - FSIS
Information Office, 1997.
National Advisory Committee on Microbiological
Criteria for Food (NACMCF). 1992 Hazard Analysis
and Critical Control Point System, Int. J. Food
Microbiology, 16:1-23.
National Food Processors Assoc. “HACCP
Implementation: A Generic Model for Chilled Foods.”
Journal of Food Protection, December, 1993, pp.
1077-1084.
President’s Council on Food Safety. The Food Safety
Strategic Plan, 2001. Ch. 2: Vision, Goals, Objectives,
and Action items. Found at:
http://www.foodsafety.gov/~fsg/cstrpl-4.html#chap2
Silliker, John, Ph.D. “Microbiological Testing and
HACCP Programs.” Dairy, Food and Environmental
Sanitation, October 1995, pp. 606-610.
Stier, R.F., and Blumenthal, M.M., Ph.D. “Will
HACCP be Carrot or Stick.” Dairy,Food and
Environmental Sanitation, October 1995, pp. 616 620.
63
Tisler, J.M. “The Food and Drug Administration’s
Perspective on HACCP,” Food Technology, June
1991, pp. 125-127.
Tompkin, R.B. “The Use of HACCP in the Production
of Meat and Poultry Products.” Journal of Food
Protection, September 1990, pp. 795-803.
Weingold, S.E. et. al. “Use of Foodborne Disease
Data for HACCP Risk Assessment.” Journal of Food
Protection, September 1994, pp. 820-830.
BOOKS
Control of Communicable Diseases in Man, 16th ed.,
American Public Health Association, 1995.
Corlett, D.A. and Pierson, M.D. HACCP, Principles &
Applications, ed., Chapman and Hall, New York,
1992.
Diseases Transmitted by Foods, 2nd ed., Centers for
Disease Control, USPHS, 1982.
Fellows, P.J. Food Processing Technology,
Principles and Practice, Ellis Horwood, New York,
1990.
Fennema, O.R. Food Chemistry, 2nd ed., Marcel
Dekker, Inc., New York, 1985.
Foodborne Diseases, ed. D.O. Cliver, Academic
Press, San Diego, California, 1990.
HACCP Reference Book, National Restaurant Assoc.,
The Educational Foundation, Chicago, 1994.
Jay, J.M. Modern Food Microbiology, 4th ed., Van
Nostrand Reinhold, New York, 1992.
Potter, N. Food Science, 4th ed., Van Nostrand
Reinhold, New York, 1986.
Procedures to Implement Hazard Analysis Critical
Control Point Systems, International Association of
64
Milk, Food and Environmental Sanitarians.
FDA PUBLICATIONS AND FEDERAL REGULATIONS
FDA Food Code, current edition, may be purchased
from the U.S. Department of Commerce, National
Technical Information Service, via telephone: (703)
487-4650 or electronically via the FDA website:
http://www.cfsan.fda.gov/~dms/foodcode.html
Fish and Fishery Products - Code of Federal Regulations, Title 21,
Part 123 Fish and Fishery Products.
Fish and Fishery Products Hazards and Controls
Guide, Third Edition, June 2001. Food and Drug
Administration, Washington, D.C. May be purchased
from:
National Technical Information Service
U.S. Department of Commerce
703-487-4650.
The Fish and Fishery Products Hazards and Controls Guide is also
available electronically at
http://www.cfsan.fda.gov/~comm/haccpsea.html
Single copies may be obtained as long as supplies
last from FDA district offices and from:
U.S. Food and Drug Administration
Office of Seafood
5100 Paint Branch Parkway
College Park, MD 20740-3835
National Shellfish Sanitation Program Model
Ordinance for Molluscan Shellfish, available on the
FDA/CFSAN website at:
http://www.cfsan.fda.gov/~ear/nsspotoc.html or may
be purchased from:
National Technical Information Service
U.S. Department of Commerce
703-487-4650.
Report of the FDA Retail Food Program Database of
Foodborne Illness Risk Factors, available on the FDA/
65
CFSAN website at:
http://www.cfsan.fda.gov/~dms/retrsk.html
FDA Report on the Occurrence of Foodborne Illness Risk Factors
in Selected Institutional Foodservice, Restaurant, and Retail Food
Store Facility Types (2004), available on the FDA/CFSAN website at:
http://www.cfsan.fda.gov/~dms/retrsk2.html
66
Annex 2 – Seafood References
This Annex is provided to assist those segments of the retail and food service industry
that deal with seafood. It is suggested that the tables that follow be used during the
hazard analysis procedural step.
Table 1. Natural Toxins1 in Seafood
Natural Toxins
Control
Paralytic Shellfish Poisoning (PSP)
Molluscan Shellfish
N.E. and N.W. coastal regions of
N. America
NSSP approved waters
2
(tags)
(FDA ICSSL listing)
Neurotoxic Shellfish Poisoning
(NSP)
Molluscan Shellfish harvested along coast
of Gulf of Mexico
NSSP approved waters
2
(tags)
(FDA ICSSL listing)
Molluscan Shellfish
NSSP approved waters
2
(tags)
(FDA ICSSL listing)
Amnesic Shellfish Poisoning (ASP)
Molluscan Shellfish
N.E. & N.W. coasts of N. America
NSSP approved waters
2
(tags)
(FDA ICSSL listing)
Ciguatera Fish Poisoning (CFP)
fin fish from extreme S.E. U.S., Hawaii,
Subtropical and Tropical areas:
barracuda
amberjack
horse-eye jack
black jack
other larger species of jack
king mackerel
large groupers
large snappers
Purchase from approved sources:
•
get fish from areas that are not
subject of an adverse advisory, or
•
get fish from a reef area known to
be monitored for toxicity and not
covered by an adverse advisory.
Gempylotoxin, a strong purgative oil
(can cause severe diarrhea)
Escolar
FDA recommendation: Escolar should
not be marketed in interstate commerce
Puffer Fish or Fugu, usually from IndoPacific ocean, however some noted from
Atlantic Ocean, Gulf of Mexico and Gulf of
California
Illegal to import or receive (exemption:
an agreement with one N.Y. importer)
Diarrhetic Shellfish Poisoning (DSP)
Etrodotoxin
1
Type of fish (species)
Fish and Fishery Products Hazards and Controls Guide, Third Edition, June 2001
2
The tags must contain a unique state issued "certification number" specific for each certified dealer. If the firm
is engaged in interstate commerce, this number appears in FDA’s Interstate Certified Shellfish Shippers List.
67
Table 2. Fish Considered to be Scombrotoxin-Forming Species1
Toxin Formation
Scombrotoxin formation as a
result of time/temperature abuse
1
Species - Market Names
Most scombroid poisonings from
tuna, mahi-mahi and bluefish.
Other species are:
Amberjack or yellowtail
Anchovy
Bluefish
Bonito
Escolar or Snake Mackerel
Gemfish
Herring (not River herring)
Jack
Jobfish
Kahawai
Mackerel (not Atka)
Mahi-Mahi
Marlin
Pilchard or Sardine
Sardine
Saury
Shad & roe
Shad, Gizzard
Snapper (Pristipomoides ssp)
Sprat or Bristling
Trevally
Tuna
Wahoo
Control
Buy from approved federally
inspected suppliers. They are
required to receive, hold, and
process using a HACCP system.
Check for an adequate quantity of
ice or other cooling media.
If not, a federally inspected
supplier or directly from a fishing
boat, check for the following at
receipt:
- an adequate quantity of ice or
other cooling media
- the time the fish were caught
(from the vessel or supplier)
- See * information below
Fish and Fishery Products Hazards and Controls Guide, Third Edition, June 2001
* FDA Recommended HACCP Controls for Histamine – Quick reference
Secondary Processor (Controls at receipt)
Transport records
OR
(< 40 ºF throughout transit)
Adequate Ice/cooling media
surrounding product at delivery
Processing/ Storage
Fresh (not previously frozen)
≤ 4 hrs @ > 40 ºF if any ≤ 8 hrs @ > 40 ºF if NO
exposure is > 70 ºF
exposure is > 70 ºF
Previously frozen
≤ 12 hrs @ > 40 ºF if
≤ 24 hrs @ > 40 ºF if
any exposure is > 70 ºF NO exposure is > 70 ºF
68
Table 3. Common Parasites in Seafood1
Parasites2
Nematodes or
roundworm
Cestodes or tapeworms
Trematodes or flukes
Type of fish/species likely
to be used in menu items
that will not be cooked
Sea bass
Capelin & roe
Cod
Flounder
- Dab
- Fluke
Grouper
Halibut
Herring
Jack
Jobfish
Kahawai
Mackerel
Monkfish
Mullet
Chilean Sea Bass
Ocean Perch
Plaice
Pollock
Rockfish
Sablefish
Salmon & roe
(aquacultured
and wild)
Seatrout
Sole
Sprat/Bristling
Trout/steelhead/
rainbow
Tuna, small
Turbot
Wolfish
Control
Purchase from a processor,
require the raw fish to have
been:
• Frozen and stored at -4
ºF (-20 ºC) or below for
7 days; or
•
Frozen at -31 ºF
(-35 ºC) or below and
stored at -31 ºF (-35 ºC)
for 15 hours; or
•
Frozen at -31 ºF
(-35 ºC) or below until
solid and stored at -4 ºF
(-20 ºC) for 24 hrs.
Freezing can be done in your
operation if it is done in
accordance with the Food Code,
Chapter 3.
1
2
Fish and Fishery Products Hazards and Controls Guide, Third Edition, June 2001
Some food products that have been implicated in human parasitic infection are:
ceviche
salmon roe
green herring
undercooked grilled fish
lomi lomi
sashimi
drunken crabs
poisson cru
sushi
cold smoke fish
69
Annex 3 – Hazard Analysis
This Annex provides guidance for determining food safety hazards in foods and/or food
preparation processes at retail. Although the hazard analysis has been kept general for
the purposes of developing your food safety management systems, it is still
recommended that you consult with your regulatory authority or other food safety
professional when conducting this procedural step.
HOW DO YOU CONDUCT A HAZARD ANALYSIS?
The purpose of hazard analysis is to develop a list of food safety hazards that are
reasonably likely to cause illness or injury if not effectively controlled. The process of
conducting a hazard analysis involves two stages:
1. Hazard Identification
2. Hazard Evaluation
Hazard identification can be thought of as a brain storming session. This stage focuses
on identifying the food safety hazards that might be present in the food given the food
preparation process used, the handling of the food, the facility, and general
characteristics of the food itself. During this stage, a review is made of the ingredients
used in the product, the activities conducted at each step in the process, the equipment
used, the final product and its method of storage and distribution, as well as the
intended use and consumers of the product. Based on this review, a list of potential
biological, chemical, or physical hazards is made at each stage in the food preparation
process.
In stage two, the hazard evaluation, each potential hazard is evaluated based on the
severity of the potential hazard and its likely occurrence. The purpose of this stage is to
determine which of the potential hazards listed in stage one of the hazard analysis
warrant control in the HACCP plan. Severity is the seriousness of the consequences of
exposure to the hazard. Considerations made when determining the severity of a
hazard include understanding the impact of the medical condition caused by the illness,
as well as the magnitude and duration of the illness or injury. Consideration of the likely
occurrence is usually based upon a combination of experience, epidemiological data,
and information in the technical literature. Hazards that are not reasonably likely to
occur are not considered in a HACCP plan. During the evaluation of each potential
hazard, the food, its method of preparation, transportation, storage, and persons likely
to consume the product should be considered to determine how each of these factors
may influence the likely occurrence and severity of the hazard being controlled.
Upon completion of the hazard analysis, a list of significant hazards that must be
considered in the HACCP plan is made, along with any measure(s) that can be used to
70
control the hazards. These measures, called control measures, are actions or activities
that can be used to prevent, eliminate, or reduce a hazard. Some control measures are
not essential to food safety, while others are.
Control measures essential to food safety like proper cooking, cooling, and refrigeration
of ready-to-eat, potentially hazardous foods are applied at critical control points (CCPs)
in the HACCP plan. The term control measure is used because not all hazards can be
prevented, but virtually all can be controlled. More than one control measure may be
required for a specific hazard. Likewise, more than one hazard may be addressed by a
specific control measure (e.g. proper cooking).
The physical characteristics and composition of the food during and after preparation
should be considered when determining the risk of a hazard. This means
understanding the intrinsic and extrinsic factors of the food that would allow conditions
that support the survival or growth of bacteria. Intrinsic factors are those that are
inherent to the food and are not readily controlled by people in a retail establishment,
such as water activity, nutrient content, and competitive microorganisms. Extrinsic
factors are those that people can readily control, such as temperature, acidity, and
availability of air.
Once the significant biological hazards are identified for a food, there are several issues
to consider when determining if conditions exist that would support their growth or
survival, including:
•
The nature of the food (ground or intact; plant or animal)
•
Whether the food is improperly cooled after cooking or improperly hot held,
(Clostridium perfringens or Bacillus cereus could grow because their spores
survive cooking and germinate)
•
Whether the food is improperly cold held (Listeria monocytogenes and Yersinia
will be a concern because they grow at refrigeration temperatures)
•
Whether foods have a high salt content (Vibrio and Staphylococcus aureus are
likely to grow because they are salt-tolerant)
•
Whether air is unavailable, such as in the interior of a cooked food or a sealed
modified-atmosphere package (Clostridium botulinum and C. perfringens will
thrive when air is not present)
•
Whether water activity is high (Staphylococcus aureus needs to have nutrients
readily available in order to thrive, but it can produce a potent toxin in a food with
a water activity that is lower than that needed by other organisms)
71
Several questions that you may ask yourself when assessing the food safety
hazards in food include the following:
•
Does the food permit survival or multiplication of pathogens and/or toxin
formation in the food before or during preparation?
•
Will the food permit survival or multiplication of pathogens and/or toxin formation
during subsequent steps of preparation?
•
What has been the safety record for the product in the marketplace? Is there an
epidemiological history associated with this food?
•
Is the food served to a highly susceptible population?
•
What is known about the time/temperature exposure of the food?
•
What is the water activity and pH of the food?
•
Have bare hands touched the food, or otherwise cross-contaminated it?
•
Is the food from a safe source?
•
Do food workers practice good personal hygiene, including frequent and effective
handwashing?
•
Has the food been exposed to unclean or unsanitized equipment?
•
Does the preparation procedure or process include a step that destroys
pathogens or their toxins? (Consider both vegetative cells and spores)
•
Is the product subject to recontamination after cooking?
Hazard identification, in conjunction with risk and severity estimation, provides a rational
basis for determining hazards of significance. There may be differences of opinion,
even among experts, as to the risk of a hazard and one may need to consult reliable
information published in peer-reviewed literature or recognized experts in the field. The
hazards must at least include those that are commonly associated with a specific
product.
A list of specific food safety hazards found in common products follows. As pointed out
in Procedural Step 3, each of these food safety hazards belong to more general
categories of hazards that may used as you develop your food safety management
system:
72
•
•
•
•
•
•
•
•
Salmonella and Campylobacter jejuni in raw poultry
Salmonella Enteriditis in undercooked eggs
E. coli O157:H7 in raw ground beef
Listeria monocytogenes in ready-to-eat foods, such as hot dogs and deli meat
Bacterial pathogens associated with unpasteurized juice or milk
Staphylococcus aureus toxin formation in ready-to-eat products that are
contaminated and later temperature-abused, such as cooked ham
Bacillus cereus spore survival and toxin formation in cooked rice
Clostridium perfringens and B. cereus spore survival and subsequent growth in
cooked meat/meat products
73
Table 1. Selected Biological and Chemical Hazards Found at Retail, Associated Foods,
and Control Measures.
HAZARD
Bacteria
ASSOCIATED FOODS
CONTROL MEASURES
Bacillus cereus
(intoxication caused by
heat-stable, preformed
emetic toxin or
toxicoinfection caused by
heat-labile, diarrheal toxin)
Campylobacter jejuni
Meat, poultry, starchy foods (rice,
potatoes), puddings, soups, cooked
vegetables
Cooking, Cooling, Cold Holding, Hot
Holding
Poultry, raw milk
Clostridium botulinum
(intoxication caused by
preformed heat-labile
toxin)
Vacuum-packed foods, reduced oxygen
packaged foods, under-processed
canned foods, garlic-in-oil mixtures,
time/temperature abused baked
potatoes/sautéed onions
Cooked meat and poultry, Cooked meat
and poultry products including
casseroles, gravies
Raw ground beef, raw seed sprouts, raw
milk, unpasteurized juice, foods
contaminated by infected food workers
via fecal-oral route
Cooking, Handwashing, Prevention of
Cross-contamination
Thermal Processing (Time + Pressure),
Cooling, Cold Holding, Hot Holding,
Acidification and Drying, etc.
Clostridium perfringens
E. coli O157:H7 (other
shiga toxin-producing E.
coli)
Listeria monocytogenes
Salmonella spp.
Shigella spp.
Staphylococcus aureus
(intoxication caused by
preformed heat-stable
toxin)
Vibrio spp.
Parasites
Anisakis simplex
Viruses
Taenia spp.
Trichinella spiralis
Hepatitis A and E
Other Viruses
(Rotaviruses, Noroviruses,
Reoviruses)
Raw meat and poultry, fresh soft cheese,
Pate, smoked seafood, deli meats, deli
salads
Meat and poultry, seafood, eggs, raw
seed sprouts, raw vegetables, raw milk,
unpasteurized juice
Raw vegetables and herbs, other foods
contaminated by infected workers via
fecal-oral route
RTE PHFs touched by bare hands after
cooking and further time/temperature
abused
Seafood, shellfish
Various fish (cod, haddock, fluke, pacific
salmon, herring, flounder, monkfish)
Beef and pork
Pork, bear and seal meat
Shellfish, any food contaminated by
infected worker via fecal-oral route
Any food contaminated by infected
worker via fecal-oral route
74
Cooling, Cold Holding, Reheating, Hot
Holding
Cooking, No Bare Hand Contact with
RTE Foods, Employee Health Policy,
Handwashing, Prevention of Crosscontamination, Pasteurization or
Treatment of Juice
Cooking, Date Marking, Cold Holding,
Handwashing, Prevention of Crosscontamination
Cooking, Use of Pasteurized Eggs,
Employee Health Policy, No Bare Hand
Contact with RTE foods, Handwashing,
Pasteurization or Treatment of Juice
Cooking, No Bare Hand Contact with
RTE Foods, Employee Health Policy,
Handwashing
Cooling, Cold Holding, Hot Holding, No
Bare Hand Contact with RTE Food,
Handwashing
Cooking, Approved Source, Prevention
of Cross-contamination
Cooking, Freezing
Cooking
Cooking
Approved Source, No Bare Hand
Contact with RTE Food, Minimizing
Bare Hand Contact with Foods Not
RTE, Employee Health Policy,
Handwashing
No Bare Hand Contact with RTE Food,
Minimizing Bare Hand Contact with
Foods Not RTE, Employee Health
Policy, Handwashing
Table 2. Foods that might be served raw or undercooked.
(Refer also to last page of Annex 2 for parasitic considerations for fish.)
Raw Animal
Food
Menu Items
Hazards
Beef
Steak Tartare
Carpaccio
Salmonella spp.
Escherichia coli O157:H7
Poultry
Duck
Salmonella spp.
Campylobacter jejuni
Eggs
Quiche, hollandaise sauce, Eggs Benedict,
homemade mayonnaise, meringue pie, some
puddings and custards, Monte Cristo sandwich,
mousse, tiramisu, chicken croquettes, rice balls,
stuffing, lasagna, french toast, crab cakes, egg
nog, fish stuffing, Caesar salad, ice cream
Salmonella Enteritidis
Raw Fish/Finfish
Lightly cooked fish, sushi, raw-marinated, coldsmoked fish, ceviche, tuna carpaccio
Anisakis simplex
Diphyllobothrium spp.
Pseudoterranova decipiens
Vibrio parahaemolyticus
Reef fish:
(barracuda, amberjack, horse-eye jack,
black/jack, other large species of jack, king
mackerel, large groupers, large snappers)
Ciguatera toxin
Shellfish
Oysters
Clams
Vibrio vulnificus
Vibrio spp.
Hepatitis A
Norovirus
Raw Dairy Products
Raw or unpasteurized milk, some soft cheeses
like Camembert, Brie, etc.
75
Listeria monocytogenes
Salmonella spp.
Campylobacter jejuni
E. coli O157:H7
Annex 4
Sample HACCP Tables
Table 1a. Process #1 – Food Preparation with No Cook Step
MENU ITEMS/PRODUCTS:
HAZARD(S)
CRITICAL
CONTROL POINTS
CRITICAL LIMITS
(List Only the
Operational Steps
that are CCPs)
MONITORING
PREREQUISITE
PROGRAMS
76
CORRECTIVE
VERIFICATION
ACTIONS
RECORDS
Table 1b. Process #1 – Food Preparation with No Cook Step
MENU ITEMS/PRODUCTS:
PROCESS
STEP
HAZARD(S)
CCP
CRITICAL LIMITS
(Y/N)
MONITORING
RECEIVE
STORE
PREPARE
HOLD
SERVE
Prerequisite
Programs
77
CORRECTIVE
VERIFICATION
ACTIONS
RECORDS
Table 2a. Process #2 – Preparation for Same Day Service
MENU ITEMS/PRODUCTS:
HAZARD(S)
CRITICAL
CONTROL
POINTS
CRITICAL LIMITS
(List Only the
Operational Steps
that are CCPs)
MONITORING
PREREQUISITE
PROGRAMS
78
CORRECTIVE
VERIFICATION
ACTIONS
RECORDS
Table 2b. Process #2 – Preparation for Same Day Service
MENU ITEMS/PRODUCTS:
PROCESS
STEP
HAZARD(S)
CCP
(Y/N)
CRITICAL LIMITS
MONITORING
RECEIVE
STORE
PREPARE
COOK
HOLD
SERVE
Prerequisite
Programs
79
CORRECTIVE
ACTIONS
VERIFICATION
RECORDS
Table 3a. Process #3 – Complex Food Preparation
MENU ITEMS/PRODUCTS:
HAZARD(S)
CRITICAL
CONTROL POINTS
CRITICAL LIMITS
(List Only the
Operational Steps
that are CCPs)
MONITORING
PREREQUISITE
PROGRAMS
80
CORRECTIVE
VERIFICATION
ACTIONS
RECORDS
Table 3b. Process #3 – Complex Food Preparation
MENU ITEMS/PRODUCTS:
PROCESS
STEP
HAZARD(S)
CCP
(Y/N)
CRITICAL LIMITS
MONITORING
RECEIVE
STORE
PREPARE
COOK
COOL
REHEAT
HOLD
SERVE
Prerequisite
Programs
81
CORRECTIVE
ACTIONS
VERIFICATION
RECORDS
Annex 5 – Paperwork Reduction Act of 1995
This manual contains information collection provisions that are subject to review
by the Office of Management and Budget (OMB) under the Paperwork Reduction
Act of 1995 (44 U.S.C. 3501-3520).
The time required to complete this information collection is estimated to average
20 hours to conduct the hazard analysis and 60 hours to develop a food safety
management system (HACCP plan), including the time to review instructions,
search existing data sources, gather the data needed, and complete and review
the information collection. Send comments regarding this burden estimate or
suggestions for reducing this burden to:
Office of Compliance
Division of Cooperative Programs (HFS-625)
Center for Food Safety and Applied Nutrition
Food and Drug Administration
5100 Paint Branch Parkway
College Park, MD 20740
An agency may not conduct or sponsor, and a person is not required to respond
to, a collection of information unless it displays a currently valid OMB control
number. The OMB control number for this information collection is 0910-0578
(expires 03/31/2009).
82
| File Type | application/pdf |
| File Title | Microsoft Word - OPERATOR'S HACCP MANUAL- PRA edits - 3-31-06.doc |
| Author | CMark |
| File Modified | 2006-04-13 |
| File Created | 2006-04-13 |