Major incidents of foodborne illness - Food Safety · and operated by the managers,supervisors and...
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Major incidents of foodborne illness Aberdeen – Typhoid 1964 – Associated with cans of corned beef cooled in sewage polluted water Stanley Royd – Salmonella 1984 – Involving cross-contamination of cooling roast beef from raw chicken resulting in 450 cases and 19 deaths Cumbria - Salmonella Ealing 1985 - Dried baby milk (Farley Health Products) resulting in 60 cases and 1 death. Caused by pinhole in silo allowing moisture to provide suitable multiplication conditions. Factory value reduced from £40 million to £18 million Wishaw – E. coli O157 1996 – Cooked cold meats and cooked steak/gravy (John Barr). Mainly cross-contamination, resulting in 500+ cases and 21 deaths. (At least 3 major outbreaks and sporadic cases) Birmingham – Clostridium botulinum 1989 – Hazelnut yogurt resulting in 27 cases and 1 death. Caused by failure to undertake a risk assessment when producing new product. (Sweetener instead of sugar (a w ) and hazelnut >pH than fruit - failure to increase processing temperature). France – Listeria monocytogenes 1992 – Pork tongue in aspic resulting in 279 cases, 63 deaths and 22 abortions USA – Salmonella Pasteurised milk resulting in 18,000 cases and 2 deaths Lawsuits in USA resulting from E. coli O157 outbreaks June 2000 – Iwan’s Deli and catering of Orland Park 1,200 ill (potato salad) - $3,000,000 May 1998 – Odwalla Inc 5 children (apple juice) - $1,200,000 February 1998 – Jack in the Box restaurant chain 4 customers died, many more ill. Accepted $58,500,000 from 9 beef suppliers (hamburgers) February 2001 – Taco hamburgers served with school lunch 11 children, 3 developed kidney problems (one serious). Court awarded $4,750,000
Transcript of Major incidents of foodborne illness - Food Safety · and operated by the managers,supervisors and...
Major incidents of foodborne illness
Aberdeen – Typhoid1964 – Associated with cans of corned beef cooled in sewage polluted water
Stanley Royd – Salmonella1984 – Involving cross-contamination of cooling roast beef from raw chickenresulting in 450 cases and 19 deaths
Cumbria - Salmonella Ealing1985 - Dried baby milk (Farley Health Products) resulting in 60 cases and 1 death.Caused by pinhole in silo allowing moisture to provide suitable multiplicationconditions. Factory value reduced from £40 million to £18 million
Wishaw – E. coli O1571996 – Cooked cold meats and cooked steak/gravy (John Barr).Mainly cross-contamination, resulting in 500+ cases and 21 deaths. (At least 3major outbreaks and sporadic cases)
Birmingham – Clostridium botulinum1989 – Hazelnut yogurt resulting in 27 cases and 1 death. Caused by failure toundertake a risk assessment when producing new product. (Sweetener insteadof sugar (aw) and hazelnut >pH than fruit - failure to increase processingtemperature).
France – Listeria monocytogenes1992 – Pork tongue in aspic resulting in 279 cases, 63 deaths and 22 abortions
USA – SalmonellaPasteurised milk resulting in 18,000 cases and 2 deaths
Lawsuits in USA resulting from E. coli O157 outbreaksJune 2000 – Iwan’s Deli and catering of Orland Park 1,200 ill (potato salad) - $3,000,000
May 1998 – Odwalla Inc5 children (apple juice) - $1,200,000
February 1998 – Jack in the Box restaurant chain 4 customers died, manymore ill. Accepted $58,500,000 from 9 beef suppliers (hamburgers)
February 2001 – Taco hamburgers served with school lunch 11 children, 3 developed kidney problems (one serious).Court awarded $4,750,000
HANDOUTDefinitionsContamination The presence or introduction of a hazard.
(EC Regulation No. 852/2004)
Control measures Actions required to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
Control point A step in the process where control may be applied, but a loss of control would not result in an unacceptable health risk.
Corrective action The action to be taken when a critical limit is breached.
Critical control point A step in the process where control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
Critical limit The value of a monitored action which separates the acceptable from the unacceptable.
Cross-contamination The transfer of bacteria from contaminated food (usually raw) to ready-to-eat foods by direct contact, drip or indirect contact using a vehicle such as the hands or a cloth.
Danger zone of The temperature range within which the multiplication of bacteriological growth most foodborne pathogenic bacteria is possible, i.e. 5ºC to
63ºC. Most rapid multiplication occurs between 20ºC and 50ºC.
Deviation Failure to meet a critical limit.
Flow diagram (chart) A systematic representation of the sequence of steps or operations involved with a particular food item or process,usually from receipt of raw ingredients to consumer.
Food hygiene The measures and conditions necessary to control hazards and to ensure fitness for human consumption of a foodstuff taking into account its intended use.(EC Regulation No.852/2004)
Food poisoning An acute illness, usually with symptoms of diarrhoea and/or vomiting, nausea and abdominal pain, caused by the consumption of contaminated or poisonous food (a multiplication of bacteria usually occurs within the food).
Food safety management The policies, procedures, practices, controls and documentation that ensure the food sold by a food business is safe to eat and free from contaminants.
HACCP (hazard analysis A food safety management system which identifies,critical control point) evaluates and controls hazards which are significant for
food safety.
HANDOUTDefinitionsHACCP team A group of people with appropriate expertise who
develop and implement a HACCP system.
Hazard A biological, chemical or physical agent in, or condition of,food with the potential to cause harm (an adverse health effect) to the consumer.
Hazard analysis The process of collecting and evaluating information on(Codex Alimentarius) hazards and conditions leading to their presence to decide
which are significant for food safety and should therefore be addressed in the HACCP plan.
High-risk food Ready-to-eat foods which, under favourable conditions,support the multiplication of pathogenic bacteria and are intended for consumption without treatment which woulddestroy such organisms.
Maintenance Maintaining the supporting elements and resources to ensure the plan remains valid over time and doesn’t become out of date.
Monitoring The planned observations or measurements ofcontrol parameters to confirm that the process is under control, and that critical limits are not exceeded.
Prerequisite programmes The good hygiene practices a business must have in place before implementing HACCP, to enable the HACCP plan to concentrate on the most significant hazards.
Review A reassessment of the HACCP system to ensure its continued validity.
Risk The likelihood of a hazard occurring in food.
Risk assessment The process of identifying hazards, assessing likelihood of occurrence and severity and evaluating the significance.
Safe food Food which is free of contaminants and will not cause illness, harm or injury.
Target level The predetermined value for the control measure, which will eliminate or control the hazard at a control point.
Tolerance The specified degree of latitude for a control measure,which, if exceeded, requires immediate corrective action.
Validation Obtaining evidence that elements of the HACCP plan are effective, especially the critical control points and critical limits.
Verification The application of methods, procedures and tests, and other evaluations, in addition to monitoring, to determine compliance with the HACCP plan. (Includes prerequisite programmes)
Origins of HACCP
Developed from the chemical processing industry HAZOPS (hazard and operability analysis)
1959 Pillsbury commissioned by NASA (Dr Howard Bauman)
1971 Presented publicly at a conference for food protection, DenverColorado
1973 Training programme on HACCP developed by Pillsbury
1974 USA FDA required HACCP principles to be applied to low-acid foods
Internationally accepted as a food safety management system
1985 National Academy of Science (USA) recommended HACCP be used by food factories to ensure food safety
1988 ICMSF (International Commission for Microbiological Standards forFood) recommended
1990 Richmond report (UK) recommended the implementation of HACCPprinciples for all stages of food production to enhance food safety
1992 NACMCF (National Advisory Committee on Microbiological Criteriafor Food) recommended HACCP
1993 Codex Alimentarius (FAO/WHO)recommended use of HACCP -developed guidelines for HACCP application - promoted as the mosteffective system of food safety assurance
1993 EC Directive 93/43
1995 Food Safety (General Food Hygiene) Regs
2000 Food Safety (General Food Hygiene) Butchers’ Shops AmendmentRegs.
2006 EC Regulation on the Hygiene of Foodstuffs
Current food poisoning trends(In England and Wales)Food poisoning - an acute illness, usually with symptoms ofdiarrhoea and/or vomiting, nausea and abdominal pain,caused by the consumption of contaminated or poisonousfood (a multiplication of bacteria usually occurs within thefood).
• Salmonella isolates from humans• Reported cases of food poisoning
(It is recommended that the statistics of reported cases arenot used to indicate trends of food poisoning or asindications of food hygiene standards. They are primarilynotifications of unconfirmed cases of suspect foodpoisoning, i.e. persons with gastroenteritis.
Furthermore, they will include a significant number of casesof campylobacter and viral illness, which are not foodborne).
Groups to provide reasons for continuing high levels offoodborne illness and food poisoning notifications.What has changed in last 10 years?
More bacteria on or in food due to:Intensive animal rearingContaminated feedConcentration - slaughterhouses and transportNB Less salmonella in chicken/eggs, but more campylobacterContaminated fruit/vegetables (salad)More public awarenessMore exotic foodMore holidays abroadMore meals away from homeImproved investigation techniquesMore susceptible people (especially aged and ill)New pathogensReduced use of preservativesChanges in preparation techniques (more bulk purchases and family meal patterns)
Food safety management
What is safe food?(Managers want the customer to return, not the food) Food which is free from contaminants and will not causeharm, injury or illness. i.e it will not cause foodpoisoning
How do we ensure the safety of food?
Food safety managementLegal and moral responsibility for every food business toimplement a food safety management system tominimise the risk of food poisoning.
A food safety management systemThe policies, procedures, practices, controls anddocumentation that ensure the food sold by a business issafe to eat and free from contaminants.
Examples of food safety management systems include:• QA and end-product testing (for manufacture);• Assured safe catering;• HACCP; • Safe Catering (NI);• Safer food, better business; • CookSafe (Scotland);• good hygiene practice, effective supervision,
generic controls and monitoring and periodic inspection.
However, many systems were poorly implemented andhad little effect on rising levels of foodborne illness.
Food hygieneThe measures and conditions necessary to controlhazards and to ensure fitness for human consumptionof a foodstuff taking into account its intended use.(EC Regulation No.852/2004)
A food business Any business in the course of which commercialoperations, with regard to food or food sources, arecarried out (whether for profit or not).
HACCPHACCP (Hazard analysis critical control point)A food safety management system which identifies, evaluatesand controls hazards which are significant for food safety.
Requires:• A multi-disciplinary approach• Full commitment and involvement of management
and workforce• Consistent/standardised production• Detailed scientific knowledge
HACCP should not be seen as an academic exercise oras mountains of monitoring records for enforcementofficers to examine during annual inspections.
HACCP should be a set of food safety rules,scientifically validated, implemented by the managerand adhered to by staff. The staff should be able todemonstrate that they understand and implementthose HACCP rules (including controls, monitoring andcorrective action) for which they are responsible.
Science and technology and HACCP are continuouslyevolving.
Practices considered good today may be consideredunacceptable tomorrow. The important thing toremember is that HACCP is a proactive food safetymanagement system which is implemented to improvefood safety and reduce the risk of foodborne illnessand injury.
Our levels of knowledge, ability and understandingvary and it is essential that the HACCP systemimplemented in a food business can be understoodand operated by the managers, supervisors and staffwithin the particular food business.
Results in continuous self-inspection
Documentation provides inspectors with current andpast conditions i.e. providing more confidence in theability of the operation to control food safety.
Implementing the principles of HACCP is a legalrequirement for most food premises within the EU
The origins of HACCPCommissioned by NASA (National Aeronautics SpaceAdministration US) in 1959 to ensure safe food was providedfor US astronauts.
First published in 1973 by Pillsbury.
Developed and promoted internationally by WHO, FAO, (Foodand Agriculture Organisation of the United Nations),NACMCF (National Advisory Committee on MicrobiologicalCriteria for Foods - US) and FSA (Food Standards Agency).
HACCP is an internationally recognised food safetymanagement system.
Codex Alimentarius Commission (CAC) claim HACCP is themost effective system of food safety assurance.
The CAC is a committee established by the FAO of theUnited Nations and WHO (World Health Organisation) todevelop internationally accepted food standards andguidelines.
Objectives - Protect the health of consumersPromote fair trade practicesFacilitate international tradePromote coordination of food standards
Representatives of government departments from all overthe world. Regular meetings held.(www.codexalimentarius.net)
Food safety management beforeHACCP
• Ad hoc identification of hazards, implementing controls, monitoring and corrective actions (good manufacturing and good hygiene practice)
• Observation and supervision of whole process by managers (QA/QC used in manufacturing to control and monitor product safety)
• Science rarely used to determine safe storage,cooking and cooling times/temperatures in catering/retailing. (Usually based on legislation/codes of practice/custom and practice)
• Emphasis usually on cleanliness and “blanket hygiene” i.e. all hygiene problems accorded equal status (exceptions e.g. retorting in canneries). Too much attention focused on walls, floors and ceilings
• Only manufacturers implemented comprehensive systems for the control of chemical & physical contaminants
• The safety of products depended on tried and tested historical systems and standards
• Caterers/retailers usually relied on advice on safe systems from enforcement officers during enforcement visits
• Manufacturers relied on end-product testing (some large retailers - random sampling)
• All sectors relied on periodic internal inspection/audit. More formal systems likely in manufacture or large retail/catering business which employed auditors
Disadvantages of end-product testing• Control is reactive, action taken after a problem• Considerable expertise to interpret results• Testing may be slow• Cost of sampling and analysis may be high• Operation controlled by scientists in ‘remote’ laboratory• Only applied to a proportion of food (limited samples)• Does not relate to all potential hazards• Limited number of staff directly involved in food safety
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ork
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(e.g
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ins
at 4
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t 48
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bab
ly
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for
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om
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ract
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fva
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us
anim
als
(pig
s,b
ird
s,d
og
s an
d c
ats)
Preparation too far in advance andstorage at ambient temperature(multiplication)
Inadequate cooling(multiplication)
Inadequate reheating(survival)
Contaminated processed/cannedfood (inherent contamination)
Undercooking(survival)
Inadequate thawing(survival during cooking)
Cross-contamination(contamination)
Raw food consumed(inherent contamination)
Improper warm holding(multiplication)
Infected food handlers(contamination)
ControlsCauses of food poisoning(hazard)
Try to complete the controls below, answers to follow
Preparation too far in advance andstorage at ambient temperature(multiplication)
Inadequate cooling(multiplication)
Inadequate reheating(survival)
Contaminated processed/cannedfood (inherent contamination)
Undercooking(survival)
Inadequate thawing(survival during cooking)
Cross-contamination(contamination)
Raw food consumed(inherent contamination)
Improper warm holding(multiplication)
Infected food handlers(contamination)
ControlsCauses of food poisoning(hazard)
• Food stored below 5°C or above 63°C• Prepare minimum amount of food• Time at ambient during preparation minimised• Staff training (personal hygiene)• Cleaning and disinfection of food contact
surfaces prior to preparation
• Food cooled from 60°C to 10°C within 1.5 hours - Blast chilling
• Food cooled from 10°C to 5°C within 1.5 hours - Blast chilling• After cooling - food stored in a refrigerator below 5°C• Weight/thickness of joints of meat controlled• Cleaning and disinfection of food contact surfaces • Staff training
• Reheat greater than 75°C at the coolest point
• Purchase all food from approved suppliers• Do not use damaged/old cans• Inspect canned contents prior to use• Staff training
• Centre temperature at least 75°C• Frozen poultry/joints thawed prior to cooking• Staff training
• Ensure poultry/joints completely thawed (thawing cabinet)• Avoid cross-contamination• Knowledge of time to thaw specific weights to
specific temperature• Staff training
• Raw and high-risk food to be segregated at all stages from delivery
• Separate food contact surfaces/equipment (colour coding)• Effective cleaning and disinfection• Staff training• High standards of personal hygiene• Effective pest control
• Hazardous raw food not to be consumed• Only use reputable suppliers• Suspect food not to be used (staff training)
• All food maintained above 63°C• Prepare minimum amount of food• Prevent contamination• Staff training
• Pre-employment medical questionnaire/screening• Screening of staff• High standards of personal hygiene• Appropriate facilities provided• Staff training, especially reporting of illness and handwashing
Hazard ranking of pathogens
Severe hazardsClostridium botulinumMycotoxins (from mould)Salmonella Typhi and ParatyphiBrucella abortusVibrio choleraeHepatitis A and BEscherichia coli O157Mycobacterium tuberculosisTaenia saginataTrichinella spiralis
Moderate hazards with potentially extensive spread (may be a severehazard for susceptible populations e.g. listeria and pregnant women)
Salmonella spp.Shigella spp.NorovirusCryptosporidiumListeria monocytogenes
Moderate hazards with limited spreadCampylobacter spp.Clostridium perfringensStaphylococcus aureusVibrio parahaemolyticusBacillus cereusGiardia lambliaYersinia enterocolitica
Examples of chemical hazards
Natural toxinsCiguatoxin (from marine dinoflagellates)Diarrhetic shellfish poisoningHaemagglutin (red kidney beans)Hydrazine derivatives (toadstools)Hydrogen cyanide (apricot kernals)Mycotoxin, for example alflotoxin and patulin from mouldParalytic shellfish poisoningPufferfish - gonads, liver and intestineSolanin (green potatoes)Scombrotoxin
Poisonous manufactured chemicalsAntibioticsBenzene (from packaging)Cleaning chemicalsDioxinsFertilisersFungicidesGrowth hormonesIndustrial waste oilPesticidesPolychlorinated biphenylsToxic metals and their compounds, including: aluminium, antimony,arsenic, cadmium, copper, cyanide, lead, mercury, tin and zincWeedkillers
In addition certain food additives are toxic if limits are exceeded, for example, monosodium glutamate, sodium nitrate and nitrite
NB also allergensCrustaceaEggsFishMilkPeanutsWheat
Physical and chemical hazards and controls
Source
Raw ingredients
Hazards Controls
Building
Equipment
Notice boards
Packaging materials
Maintenanceoperatives
Food handlers andvisitors
Cleaning activities
Try to complete the hazards and controls, answers to follow
Physical and chemical hazards and controls
Source
Pests
Hazards Controls
Pesticides
Industrial chemicals
Sabotage
Food containers (jars andbottles used for filling, e.g.jam)
Physical and chemical hazards and controls
Source
Raw ingredients
Hazards Controls
Building
Equipment
Notice boards
Packaging materials
Maintenanceoperatives
Food handlers andvisitors
Cleaning activities
Natural poisons Approved suppliersStones/bones/dirt Product specification/routine checkingGlass Cleaning/washing/inspectionPests/pest debris Optical systemsWood Air/liquid separationCigarette ends Illuminated inspection belts/spottersMetal - nails/wire/nuts Sieving/filtrationPlastic Metal detection/x-ray/magnets
Flaking paint/rust/nails Maintenance programmeCondensation Replace worn and damaged surfacesGlass - light-fittings/windows Effective ventilation/cover food/enclosed systemsInsulation Glass policyWood
Bolts/nuts Metal detection/self-locking/maintenanceGrease/oil Staff training (not above open food)Glass Use perspex/glass policyWood Wood policy
Drawing pins Not to be used. Perspex covered notice boards
Staples Specify packaging eg tape, not staplesString Strict instructions on un-packaging/de-boxingWood/plastic (pallets & boxes) Remove secondary packaging before entering high-Containers risk areas. Clean on arrivalPlastic Separate de-boxing areasGlass Strict rejection policies if contaminated
Swarf Training of maintenance operatives Screws/nuts/bolts Cleaning and inspection after maintenanceWire Metal detectionFibres/cloth Avoid maintenance during food production/remove
food and food equipment from food areas
Jewellery High standards of personal hygieneButtons Staff trainingPen tops/cigarette ends Strict rules enforcedDressings Visitors to wear protective clothing
No eating/smoking
Plastic slivers Regular checking/replacement of suspect equipmentChemicals Use of correct equipment/chemicals (not phenols)
Training of cleanersNo inappropriate methods eg high pressurespraying near open food
HANDOUTPhysical and chemical hazards and controls
Source
Pests
Hazards Controls
Pesticides
Industrial chemicals
Sabotage
Food containers (jars andbottles used for filling, e.g.jam)
Bodies Effective pest controlDroppings Prevent entryWebbing Correct storage and rotationLarvae/eggs Training of operatives to spot and report signsFeathers Reject potentially contaminated food
Physical control preferableCorrect siting of electric fly killers
Spraying on food/ Control systems/approved contractorsequipment Operator/staff trainingContaminated raw Cleaner trainingmaterials Approved suppliers
Contaminated raw Approved suppliersmaterialsFreezer breakdown Segregation/leaks(leaking refrigerants) Staff trainingVeterinary drugs/fertilisers Note distribution/delivery vehiclesEnvironmental contamination eg dioxins
Needles Tamper evident packagingRazor blades VigilanceToothpicks Thorough investigation of complaints (deterent effect)Glass
Glass shards Approved supplier/correct glassCareful handling/distribution/unloadingStaff training, effective supervisionInversion and cleaning (compressed air/water jets)Protect after cleaning prior to fillingEffective procedures for dealing with breakage
Chemical contamination Effective/cleaning/rinsing/emptying
HazardsA biological, chemical or physical agent in, orcondition of, food with the potential to cause harm (anadverse health effect) to the consumer. (Mostbiological hazards are microbiological).
Microbiological hazardThe unacceptable contamination, the unacceptablemultiplication, the unacceptable production orpersistence of toxins and/or the unacceptable survivalof pathogenic microorganisms in food. (Includesbacteria, viruses, parasites, protozoa and moulds.)
Microbiological hazards result in foodborne disease orfood poisoning.May be present in raw materials.Cross-contamination of high-risk food by pathogens.Multiplication/toxin production.Survival of pathogens/spores/toxins during cooking,preservation or processing.
Chemical hazards result in food poisoning or chronicillness such as cancer.
Present in raw materials.Contamination by cleaning agents.
by pesticides.by weedkillers.by allergens.
Excess additivesPoisonous foods e.g. toadstools.
Physical hazards are foreign bodies in food which maycause cuts to mouth, choking, broken teeth or internalinjury, for example, glass, nails or stones. May alsoinclude burning if food is too hot. Physical hazards maybe present in raw ingredients or introduced duringproduction/preparation.
Failure to control food hazards1964 - Aberdeen Typhoid outbreak. Argentinian
corned beef - cans cooled in polluted river water. SalmonellaTyphi entered through seams.Cross-contamination to other meatsduring slicing (from slicing machine) 400+ cases
1984 - Wakefield Stanley Royd HospitalSalmonella Typhimurium 455 cases,19 deaths. Cross-contamination between thawing frozen poultry and cooling beef from the oven thought to be the likely cause.Resulted in the end of Crown immunity for hospital kitchens fromlocal authority enforcement action.Also resulted in major introduction of cook-chill operations in hospitals.
1989 - Birmingham 27 cases and 1 death from Clostridium botulinum following the consumption of hazelnut yoghurt. Manufacturer previously produced fruit yoghurts. No effective hazard analysis when changing to hazelnut. Higher pH requires increased processing temperatures also changed from sugar to saccharin which increased the aw, allowing the germination of spores.
1996 - J Barr Wholesale Butcher . SeveralWishaw outbreaks of E.coli O157. 500+ Scotland cases, 21 deaths. Main problem
was a failure to understand the risksinvolved when producing cooked meat. No HACCP in place. Cross-contamination a major hazard and possibly the failure to cook and reheat thoroughly. Some outbreaksinvolved cross-contamination of other cooked meats (similar to Aberdeen Typhoid outbreak)
Failure to control food hazards
The adverse effects of food poisoning/foodcomplaints on a food business
The resources (time, personnel, money) involved ininvestigation and report writing.
Brand damage.
The adverse publicity and potential loss of business.
Prosecution - fines, closure, improvement notices andbanning from operating a food business.
Civil action resulting in compensation.
Overall loss of public confidence in specific foods andthe food industry e.g. eggs.
Microbiological hazards(Foodborne pathogens)
BacteriaThe main cause of food poisoning.
VirusesHepatitis ANorovirus
Viral gastroenteritisQuite common but usually relatively mild. Oftenspread by the faecal/oral route and from theenvironment. Usually low dose. Norovirus quitecommon but under-reported because of relativelymild illness for short period of time.
ProtozoaCryptosporidium parvumGiardia lamblia (faecal/oral route, waterborne outbreaks)
Moulds (fungi)Aspergillus spp. produce mycotoxinsAflatoxin (nuts) Patulin (apple juice)
ParasitesTaenia saginata (beef)Trichina spiralis (pork and horse flesh)
Algae Poisonous dinoflagellates which produce biotoxinscausing paralytic and diarrhetic shellfish poisoning
Microbiological hazards
Sources of pathogensPeople
• Hands • Nose, sneezing• Mouth • Hair• Skin cuts and grazes • Intestines• Sewage
Raw food/water/ice• Red and white meat• Raw vegetables (soil)• Milk• Eggs• Shellfish (especially bivalves)• Ready-to-eat fruit/salad vegetables
- contaminated irrigation- poor hygiene of harvesters- contaminated in transport (manure
transported one way, lettuces the other)
NB Suspected that the outbreak of Novovirus amongstBritish Troops in Afghanistan resulted from sewagecontamination of their drinking water.
Soil/dust• Cover food
Animals and birds• No access to pets etc.
Insects• Flies, cockroaches etc. (from feet, vomit, faeces etc.)
Rodents• Rats, mice (from feet, urine, faeces, mouths etc.)
Refuse and waste food• Do not allow waste to accumulate
NB Norovirus - inhalation of dust from desiccatedvomit and faeces may occur.
57
Microbiological hazards
SporesResistant resting phase of certain bacteria, e.g.Clostridium perfringens, which protects them againstadverse conditions, such as high temperatures,chemicals and dehydration.• Survive for many years• Activated by cooking• Germinate during cooling• Unaffected by refrigeration or freezing
ToxinsPoisons produced by pathogens. They may beproduced in the food or in the body after the food hasbeen eaten. Toxins are unaffected by refrigeration orfreezing.
• Exotoxins: Usually formed in food, e.g.Staphylococcus aureus. Many exotoxins are very heat-resistant and boiling for long periods may be requiredto ensure their destruction. Normal cooking may notdestroy them. Eating foods containing toxins is likelyto result in food poisoning. C. perfringens produces anexotoxin in the intestine when spores are formed.
• Endotoxins: Usually produced in the body, e.g.Salmonella. Once again if sufficient toxin is present wewill end up with food poisoning.
NB This OHP is optional depending on group knowledge.
58
Microbiological hazardsFactors affecting the multiplication of foodborne pathogens
Danger zone for bacterial growthThe temperature range within which the multiplication ofmost foodborne pathogenic bacteria is possible i.e. 5ºC to63ºC. (Some pathogens grow outside this range, e.g. listeriaand Clostridium botulinum (3.3ºC) grow below 5ºC; somepathogens may not start growing until at least 10ºC, e.g.Clostridium perfringens. No foodborne pathogens multiplyabove 52ºC.)
• Temperature (5°C to 63°C optimum 20°C to 50°C)• Time (as short as 10 minutes)• pH (dislike extremes of pH e.g. acid food<4.5)• aw (available moisture) (usually sufficient in most
foods)• Oxygen presence or absence• Nutrients (Food) (usually protein)• Preservatives e.g. salt, nitrate
Large numbers of bacteria usually required to cause foodpoisoning (pathogens low-dose).Foodborne diseases including E. coli O157, hepatitis A,dysentery (shigella), typhoid and viral gastroenteritis havelow infective doses and do not need to multiply in food,although E. coli O157 can do so.Bacteria multiply by dividing into two. Binary fission. 10-20minutes in optimum conditions 1000 to 1,000,000 in 1 hour40 minutes (every 10 minutes).Important UK foodborne pathogens - sources, vehicles,growth characteristics and infective doses.
Control measures• Keep food out of the danger zone below 5°C or above 63°C• Minimise time at room temperature• Remove moisture and keep dry foods free from
moisture (dehydration)• Preservatives, e.g. salt and sugar or acid (vinegar)• Fermentation e.g. salami, yogurt and cheese
Destroying bacteria • Heat processing/cooking - centre temperature 75ºC
(or equivalent time/temp)• Stews etc. (usually around 100°C)
• Reheat to a minimum 75°C (82ºC in Scotland)• Pasteurization, sterilization, canning (121°C for 3
minutes)• Disinfectants such as bleach• Irradiation (spices) and U/V light (water/oysters)
Destroying unfit, suspect or contaminated food.
In manufacturing, for example canning, a knowledgeof the specific pathogen is essential to ensure effectivecontrol.However, in catering a generic control is usuallyapplied, for example, cook to a core temperature of75ºC.
Microbiological hazards
Discuss sources of important pathogens (generic orspecific)
Consider:If raw ingredients are a possible source ofpathogens/toxins
If raw ingredients have been treated to destroypathogens
Food vehicles of pathogens:• Raw milk/dairy products: E. coli O157, salmonella ,
campylobacter,Staphylococcus aureus
• Uncooked egg products: salmonella• Cooked meat: E. coli O157, salmonella and
Staphylococcus aureus• Rice: Bacillus cereus• Bivalves: Norovirus• Salad vegetables/fruit: E. coli O157, salmonella,
norovirus, Hepatitis A and protozoa• Salmon/trout (especially smoked/vacuum packed):
Clostridium botulinum
Physical hazards (foreign bodies)
Physical hazards may make the food unsafe forconsumption, and usually result in complaints.
Effects of physical hazards:Choking )Cuts/penetration) may require surgery to removeBroken teeth )Burning )NB Long-term effect
Physical hazards which do not make the food unsafeneed to be removed for quality reasons and to complywith the requirements of the food safety legislation,e.g. paper, small pieces of soft packaging material.
Sources of physical hazardsMay be brought in with raw ingredients or duringtransport (unloading and loading) e.g. wood fromcrates or pallets, especially if double stacked.
BUILDINGS - (walls, ceilings, pipework, doors, windows)flaky paint, condensation, glass, rust etc.EQUIPMENT - nuts, bolts, flaking paint, rust etc.NOTICE BOARDS - drawing pins.FOOD HANDLERS/VISITORS - jewellery, pen tops,buttons.MAINTENANCE OPERATIVES - swarf, wire, pens, nuts,bolts, screws.PACKAGING MATERIALS - wire, nails, screws, wood,glass.PESTS - bodies, eggs and droppings.PEST CONTROL ACTIVITIES - bait boxes, plastic, bait.CLEANING ACTIVITIES - wood, plastic, bristles.FOOD CONTAINERSRESULT OF POST-PROCESS CONTAMINATION -sabotage.
Sources of chemical hazardsPresent in raw materials
Pesticides/herbicides/fungicides/fertilizers (vegetables).Heavy metals e.g. lead, zinc, mercury, (vegetables, fish).Antibiotics/hormone residues(meat).Allergens e.g. peanuts, crustacea, eggs, sesame seeds,celery, mustard, fish, milk, soy and wheat (gluten)Natural toxins e.g. rhubarb leaves, solanin (green potatoes)Industrial chemicals e.g. dioxins in milk, PCBS(polychlorinated byphenyls)Radiation (Chernobyl)
Contamination during processingFumes - paint, petrolCleaning chemicals - especially 'Cleaning in Place' causticsoda.LubricantsPesticides - rat poisoning, insect sprays.Allergens - processed food, sweets, cereals (cross-contamination). (Clear labelling is essential).Excess additives - nitrates, sulphites, monosodiumglutamate.Migration from packaging - inks, plasticisers, adhesives.SabotageChemical poisoning may be acute, chronic orcarcinogenic.
May be difficult to control if we don’t know the toxicitylevels
64
MODULE 3
Prerequisite programmes
Outcomes
The delegate will know and understand how to:
• define control measures
• explain the relationship between HACCP and prerequisite programmes
• provide examples of prerequisite programmes
• describe the importance of management commitment to implement HACCP and to provide leadership and resources
• explain the importance of approved suppliers andsupplier assurance
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(GC
A)
Cle
anin
g c
on
tro
l ch
art
Pre
req
uis
ites
- C
lean
ing
an
d d
isin
fect
ion
Haz
ard
s - B
acte
rio
log
ical
,ch
emic
al a
nd
ph
ysic
al c
on
tam
inat
ion
.Su
rviv
al o
f p
ath
og
ens.
Sou
rces
an
d/o
r ca
use
s o
f h
azar
ds
Co
ntr
ol m
easu
res
Mo
nit
ori
ng
Co
rrec
tive
act
ion
Cro
ss-c
on
tam
inat
ion
fro
mco
nta
min
ated
cle
anin
g e
qu
ipm
ent
and
/or
clea
nin
g r
aw f
oo
d a
reas
bef
ore
hig
h-r
isk
area
s
Failu
re t
o d
estr
oy
pat
ho
gen
s
Ch
emic
al c
on
tam
inat
ion
of
foo
de.
g.t
ain
tin
g w
ith
ph
eno
ls
Ph
ysic
al c
on
tam
inat
ion
of
foo
dfr
om
cle
anin
g e
qu
ipm
ent
e.g
.b
rist
les
fro
m b
rush
es
Have a go at this one, answers to follow
HA
ND
OU
T
Cle
anin
g c
on
tro
l ch
art
AN
SWER
SP
rere
qu
isit
es -
Cle
anin
g a
nd
dis
infe
ctio
nH
azar
ds
- Bac
teri
olo
gic
al,c
hem
ical
an
d p
hys
ical
co
nta
min
atio
n.S
urv
ival
of
pat
ho
gen
s.
Sou
rces
an
d/o
r ca
use
s o
f h
azar
ds
Co
ntr
ol m
easu
res
Mo
nit
ori
ng
Co
rrec
tive
act
ion
Dis
card
/des
tro
y u
nfi
t fo
od
Ch
ang
e cl
ean
ing
sch
edu
leIm
pro
ve t
rain
ing
/in
stru
ctio
n/s
up
ervi
sio
nP
rovi
de
add
itio
nal
cle
anin
g e
qu
ipm
ent
Re-
clea
n a
nd
dis
infe
ct s
urf
aces
/eq
uip
men
tC
han
ge
clea
nin
g c
hem
ical
s/eq
uip
men
tIm
pro
ve t
rain
ing
/su
per
visi
on
/in
stru
ctio
n
Dis
card
/des
troy
co
nta
min
ated
fo
od
Imp
rove
tra
inin
g/s
up
ervi
sio
n/i
nst
ruct
ion
Ch
ang
e st
ora
ge
arra
ng
emen
ts
Rep
lace
/rep
air
equ
ipm
ent
Dis
card
/des
troy
co
nta
min
ated
fo
od
Au
dit
/ch
eck
clea
nin
g s
ched
ule
sA
TP/s
wab
bin
gC
om
pet
ency
tes
tin
g o
f st
aff/
sup
ervi
sors
Au
dit
/in
spec
tio
nA
TP/s
wab
bin
g
Co
mp
eten
cy t
esti
ng
Au
dit
s/in
spec
tio
ns
Insp
ecti
on
of
clea
nin
g e
qu
ipm
ent
Effe
ctiv
e cl
ean
ing
an
d d
isin
fect
ion
(use
sch
edu
les)
Cle
an a
nd
dis
infe
ct c
lean
ing
eq
uip
men
t af
ter
use
Use
sep
arat
e cl
ean
ing
eq
uip
men
t fo
r h
igh
-ris
kan
d r
aw f
oo
d a
reas
Effe
ctiv
e tr
ain
ing
/in
stru
ctio
n a
nd
su
per
visi
on
of
clea
nin
g s
taff
Follo
w m
anu
fact
ure
r’s
inst
ruct
ion
s C
orr
ect
chem
ical
s/co
nta
ct t
ime
Effe
ctiv
e tr
ain
ing
/in
stru
ctio
n a
nd
su
per
visi
on
Follo
w m
anu
fact
ure
r’s
inst
ruct
ion
sSt
ore
cle
anin
g c
hem
ical
s se
par
atel
y
Use
th
e ri
gh
t cl
ean
ing
eq
uip
men
t in
go
od
con
dit
ion
Cro
ss-c
on
tam
inat
ion
fro
mco
nta
min
ated
cle
anin
g e
qu
ipm
ent
and
/or
clea
nin
g r
aw f
oo
d a
reas
bef
ore
hig
h-r
isk
area
s
Failu
re t
o d
estr
oy
pat
ho
gen
s
Ch
emic
al c
on
tam
inat
ion
of
foo
de.
g.t
ain
tin
g w
ith
ph
eno
ls
Ph
ysic
al c
on
tam
inat
ion
of
foo
dfr
om
cle
anin
g e
qu
ipm
ent
e.g
.b
rist
les
fro
m b
rush
es
Pes
t co
ntr
ol c
har
tP
rere
qu
isit
es -
Pes
tsH
azar
ds
- Bac
teri
olo
gic
al &
ph
ysic
al c
on
tam
inat
ion
(fro
m p
ests
).C
hem
ical
fro
m p
esti
cid
es.
Sou
rces
an
d/o
r ca
use
s o
f h
azar
ds
Co
ntr
ol m
easu
res
Mo
nit
ori
ng
Co
rrec
tive
act
ion
Co
nta
min
atio
n o
f fo
od
an
d f
oo
dco
nta
ct s
urf
aces
fro
m p
ests
Flie
s d
rop
ped
ou
t o
f EF
Ks
on
tofo
od
or
foo
d c
on
tact
su
rfac
es
Co
nta
min
atio
n o
f fo
od
or
foo
dco
nta
ct s
urf
aces
wit
h p
esti
cid
e
Another one to complete, answers to follow
HA
ND
OU
T
Pes
t co
ntr
ol c
har
t A
NSW
ERS
Pre
req
uis
ites
- P
ests
Haz
ard
s - B
acte
rio
log
ical
& p
hys
ical
co
nta
min
atio
n (f
rom
pes
ts).
Ch
emic
al f
rom
pes
tici
des
.
Sou
rces
an
d/o
r ca
use
s o
f h
azar
ds
Co
ntr
ol m
easu
res
Mo
nit
ori
ng
Co
rrec
tive
act
ion
Seg
reg
ate/
reje
ct/d
estr
oy
con
tam
inat
ed f
oo
dTh
oro
ug
h c
lean
ing
an
d d
isin
fect
ing
of
con
tam
inat
edsu
rfac
es,e
spec
ially
fo
od
an
d h
and
co
nta
ct s
urf
aces
Cal
l in
,or
rep
lace
,co
ntr
acto
rIs
sue
new
pro
ced
ure
s/in
stru
ctio
ns
to s
taff
Imp
lem
ent
reco
mm
end
atio
n f
rom
pes
t co
ntr
ol c
on
trac
tor
Imp
rove
tra
inin
g,i
nst
ruct
ion
,mo
tiva
tio
n a
nd
su
per
visi
on
of
staf
fR
epla
ce d
efec
tive
U/V
tu
bes
in E
FKs
Rep
osi
tio
n E
FKs
(Des
tro
y co
nta
min
ated
fo
od
)
Dis
card
/des
troy
co
nta
min
ated
fo
od
Issu
e n
ew in
stru
ctio
ns
Rep
lace
co
ntr
acto
r
Reg
ula
r au
dit
s/in
spec
tio
ns
Ch
eck
pes
t co
ntr
ol b
oo
kC
hec
k EF
Ks/
bai
tbo
xes
Ch
eck
cust
om
er c
om
pla
ints
Au
dit
/in
spec
tio
n
Insp
ecti
on
/ob
serv
atio
n
Inte
gra
ted
pes
t m
anag
emen
t,in
clu
din
gef
fect
ive
mai
nte
nan
ce,p
roo
fin
g,g
oo
dh
ou
seke
epin
g a
nd
co
ntr
ol.
Foo
d s
tore
d in
pes
t-p
roo
f co
nta
iner
sU
se o
f re
pu
tab
le p
est
con
tro
l co
ntr
acto
rSt
aff
vig
ilan
ce/r
epo
rtin
g/t
rain
ing
Sto
re p
rod
uct
s o
ff f
loo
r an
d a
way
fro
m w
all.
Do
n’t
leav
e u
nd
istu
rbed
fo
r p
rolo
ng
edp
erio
ds.
Po
siti
on
of
EFK
s
Rem
ove
fo
od
etc
.bef
ore
tre
atm
ent
Cle
an s
urf
aces
aft
er t
reat
men
t U
se r
epu
tab
le c
on
trac
tor
Co
nta
min
atio
n o
f fo
od
an
d f
oo
dco
nta
ct s
urf
aces
fro
m p
ests
Flie
s d
rop
ped
ou
t o
f EF
Ks
on
to f
oo
do
r fo
od
co
nta
ct s
urf
aces
Co
nta
min
atio
n o
f fo
od
or
foo
dco
nta
ct s
urf
aces
wit
h p
esti
cid
e
Was
te m
anag
emen
t co
ntr
ol c
har
tP
rere
qu
isit
es -
Was
te m
anag
emen
tH
azar
ds
- Bac
teri
olo
gic
al a
nd
ph
ysic
al c
on
tam
inat
ion
Sou
rces
an
d/o
r ca
use
s o
f h
azar
ds
Co
ntr
ol m
easu
res
Mo
nit
ori
ng
Co
rrec
tive
act
ion
Ove
rflo
win
g w
aste
rec
epta
cles
attr
acti
ng
pes
ts
Un
cove
red
ext
ern
al w
aste
con
tain
ers
attr
acti
ng
pes
ts
Dec
om
po
sin
g/m
agg
ot
infe
sted
was
te
Exte
rnal
was
te s
tora
ge
con
tain
ers
wro
ng
ly s
ited
Last one to complete, answers to follow
HA
ND
OU
T
Was
te m
anag
emen
t co
ntr
ol c
har
t A
NSW
ERS
Pre
req
uis
ites
- W
aste
man
agem
ent
Haz
ard
s - B
acte
rio
log
ical
an
d p
hys
ical
co
nta
min
atio
n
Sou
rces
an
d/o
r ca
use
s o
f h
azar
ds
Co
ntr
ol m
easu
res
Mo
nit
ori
ng
Co
rrec
tive
act
ion
Dis
card
co
nta
min
ated
foo
d
Ref
resh
er t
rain
ing
of
staf
f/su
per
viso
rs
Imp
rove
d s
up
ervi
sio
n/i
nst
ruct
ion
Pro
visi
on
of
new
was
te r
ecep
tacl
e
Ch
ang
e sy
stem
to
red
uce
am
ou
nt
of
was
te p
rod
uce
d
Incr
ease
fre
qu
ency
of
colle
ctio
n
Res
ite
exte
rnal
was
te s
tora
ge
area
s
Reg
ula
r ch
eck
ing
of
syst
ems/
pro
ced
ure
s an
dw
aste
co
nta
iner
s
Co
mp
eten
cy t
esti
ng
of
staf
f/su
per
viso
rs
Au
dit
s
Suit
able
an
d s
uff
icie
nt
was
te r
ecep
tacl
es
Staf
f vi
gila
nce
/tra
inin
g/s
up
ervi
sio
n
Sup
ervi
sio
n (w
aste
no
t al
low
ed t
o a
ccu
mu
late
)
Site
ext
ern
al w
aste
are
as t
o m
inim
ise
risk
of
con
tam
inat
ion
to
fo
od
/fo
od
eq
uip
men
t o
rst
aff
Ove
rflo
win
g w
aste
rec
epta
cles
attr
acti
ng
pes
ts
Un
cove
red
ext
ern
al w
aste
con
tain
ers
attr
acti
ng
pes
ts
Dec
om
po
sin
g/m
agg
ot
infe
sted
was
te
Exte
rnal
was
te s
tora
ge
con
tain
ers
wro
ng
ly s
ited
Prerequisites programmes(Include GHP/GMP/employee training)
Prerequisite programmes are the good hygiene practicesa business must have in place before implementing theHACCP plan.
Prerequisite programmes ensure the HACCP planconcentrates on the most significant hazards. Theeffectiveness of prerequisite programmes isdetermined by carrying out internal audits.
PrerequisitesManagement commitment
Adequate resources and suitable facilities
Approved suppliers (discuss supplier assurance e.g.auditing, customer reference, history,specifications/sampling, brand, documentation, othercustomers used.)
Premises and equipment well designed, constructed andmaintained.
Unidirectional product flow.
Potable water/ice supplies
Prerequisites programmes(Include GHP/GMP/employee training)
High standards of personal hygiene. (Suitable facilities).Health and exclusion policy. Visitor policy/contractorpolicyStaff trained commensurate with their work activitiesEffective planned cleaning and disinfection(schedules). Suitable facilitiesEquipment calibrationPreventive maintenanceStock rotationIntegrated pest managementEffective waste managementLabelling, traceability and recall procedures
NB Quite often where outbreaks of food poisoning have beenlinked to HACCP certified food operations, the breakdown hasbeen associated with inadequate prerequisite programmes.
Control measuresActions required to exclude or eliminate a food safetyhazard or reduce it to an acceptable level.
MODULE 4
Legal requirements and HACCPprinciples
Outcomes
The delegate will know and understand how to:• define hazard analysis
• explain how the obligation to produce safe food has been incorporated into national and trade agreements
• explain how the EU Hygiene Directive 93/43 has been incorporated into UK Food Safety Legislation (will be replaced by EC Regulation No 852/2004 on the Hygiene of Foodstuffs from 01/01/06)
• explain the role of Industry Guides to Good Hygiene Practice
• describe the elements of food safety managementsystems based on hazard analysis
• state the 7 principles of HACCP as defined by Codex Alimentarius
• explain the benefits of Food Safety Management Systems based on the principles of HACCP
• explain the roles of employees and managers regarding food safety and HACCP
• provide examples of useful HACCP reference sources and relevant legislation
Legal requirement for hazard analysis
The Food Safety (General Food Hygiene) Regulations, 1995Regulation 4(3) - A proprietor of a food business shall ensure that the
preparation, processing, manufacturing, packaging, storing, transportation,distribution, handling and offering for sale or supply of food are carried outhygienically. (In particular, the proprietor must ensure that the appropriaterequirements of Schedule are complied with.)
The proprietor shall identify any step in the activities of the food businesswhich is critical to ensuring food safety and ensure that adequate safetyprocedures are identified, implemented, maintained and reviewed on the basisof the following principles:
• Analysis of the potential food hazards.• Identify the points where the hazards may occur.• Decide which of the points are critical to food safety.• Implement effective control and monitoring at CCPs.• Review the system periodically and whenever significant change occurs.
NB Although the two missing HACCP principles (verification anddocumentation) are not legal requirements many people consider them to beimportant for a well run business.
REGULATION (EC) No 852/2004 ON THE HYGIENE OF FOODSTUFFSDate of application 1 January 2006 Article 5
1. Food business operators shall put in place, implement and maintainpermanent procedures based on the following HACCP principles:
(a) identifying any hazards that must be prevented, eliminated or reduced to acceptable levels;
(b) identifying the critical control points at the step or steps at which control is essential to prevent or eliminate a hazard or to reduce it to acceptable levels;
(c) establishing critical limits at critical control points which separate acceptability from unacceptability for the prevention, elimination or reduction of identified hazards;
(d) establishing and implementing effective monitoring procedures at critical control points;
(e) establishing corrective actions when monitoring indicates that a critical control point is not under control;
(f ) establishing procedures, which shall be carried out regularly, to verify that the measures outlined in subparagraphs (a) to (e) are working effectively; and
(g) establishing documents and records commensurate with the nature andsize of the food business to demonstrate the effective application of the measures outlined in subparagraphs (a) to (f ).
When any modification is made in the product, process, or any step, foodbusiness operators shall review the procedure and make the necessarychanges to it.
Paragraph 1 shall apply only to food business operators carrying out anystage of production, processing and distribution of food after primaryproduction and those associated operations listed in Annex I.
Food business operators shall:(a) provide the competent authority with evidence of their compliance with
paragraph 1 in the manner that the competent authority requires,taking account of the nature and size of the food business;
(b) ensure that any documents describing the procedures developed in accordance with this Article are up to date at all times;
(c) retain any other documents and records for an appropriate period.
ANNEX 11 Chapter XII TrainingFood business operators are to ensure:1. that food handlers are supervised and instructed and/or trained in food
hygiene matters commensurate with their work activity;2. that those responsible for the development and maintenance of the
procedure referred to in Article 5(1) of this Regulation or for the operation of relevant guides have received adequate training in the application of the HACCP principles; and
3. compliance with any requirements of national law concerning training programmes for persons working in certain food sectors.
7 HACCP principles (Codex Alimentarius)
1 Conduct a hazard analysis. Prepare a flow diagram, identify the hazards and specify the control measures.
2 Determine the critical control points.
3 Establish critical limits, target levels and tolerances.
4 Establish a monitoring system by scheduled testing or observations.
5 Establish corrective actions to be taken when a CCP is out of control.
6 Establish verification procedures which include appropriate supplementary tests together with a review which confirms that HACCP is working effectively.
7 Establish documentation concerning all procedures and records appropriate to these principles and their application.
Legal requirement for HACCP
Hazard analysisThe process of collecting and evaluating information onhazards and conditions leading to their presence todecide which are significant for food safety and shouldtherefore be addressed in the HACCP plan. (CodexAlimentarius)
EU directive 93/43 Food Safety (General Food Hygiene)Regs 1995Codes of Practice - guidance for enforcement officersIndustry Guides to Good Hygiene Practice - advice oncompliance
NB Vertical directives relate to a specific food industry e.g.red meat or poultry. Horizontal directives apply to all foodpremises. The current strategy from the EU is to usehorizontal directives as far as practicable.
Food Safety Act 1990 - due diligence defence
Discuss how HACCP is a vital part of a due diligencedefence, especially accurate and relevant documentationand records.
The section Compliance ComplianceAll reasonable An effective control HACCPprecautions system
Due diligence Implementation Effectiveof the control implementationsystem of HACCP
Legal requirement for hazardanalysis
The Food Safety (General Food Hygiene)Regulations, 1995
Regulation 4(3) - A proprietor of a food business shallensure that the preparation, processing,manufacturing, packaging, storing, transportation,distribution, handling and offering for sale or supplyof food are carried out hygienically. (In particular, theproprietor must ensure that the appropriaterequirements of Schedule are complied with.)
The proprietor shall identify any step in the activities ofthe food business which is critical to ensuring food safetyand ensure that adequate safety procedures areidentified, implemented, maintained and reviewed onthe basis of the following principles:
• Analysis of food hazards.• Identify the points where the hazards may occur.• Decide which of the points are critical to food safety.• Implement effective control and monitoring at CCPs.• Review the system periodically and whenever
significant change occurs.
REGULATION (EC) No 852/2004 ONTHE HYGIENE OF FOODSTUFFSEarliest date of application 1 January 2006 Article 5
1. Food business operators shall put in place, implementand maintain permanent procedures based on thefollowing HACCP principles:
(a) identifying any hazards that must be prevented,eliminated or reduced to acceptable levels;
(b) identifying the critical control points at the step or steps at which control is essential to prevent or eliminate a hazard or to reduce it to acceptable levels;
(c) establishing critical limits at critical control points which separate acceptability from unacceptability forthe prevention, elimination or reduction of identified hazards;
(d) establishing and implementing effective monitoring procedures at critical control points;
(e) establishing corrective actions when monitoring indicates that a critical control point is not under control;
(f ) establishing verification procedures, which shall be carried out regularly, to verify that the measures outlined in subparagraphs (a) to (e) are working effectively; and
(g) establishing documents and records commensurate with the nature and size of the food business to demonstrate the effective application of the measures outlined in subparagraphs (a) to (f).
When any modification is made in the product, process,or any step, food business operators shall review theprocedure and make the necessary changes to it.
Paragraph 1 shall apply only to food business operatorscarrying out any stage of production, processing anddistribution of food after primary production and thoseassociated operations listed in Annex I.
Food business operators shall:(a) provide the competent authority with evidence of
their compliance with paragraph 1 in the manner thatthe competent authority requires, taking account of
the nature and size of the food business;(b) ensure that any documents describing the
procedures developed in accordance with this Article are up to date at all times;
(c) retain any other documents and records for an appropriate period.
ANNEX 11 Chapter XII TrainingFood business operators are to ensure:1. That food handlers are supervised and instructed
and/or trained in food hygiene matters commensurate with their work activity;
2. That those responsible for the development and maintenance of the procedure referred to in Article 5(1) of this Regulation or for the operation of relevant guides have received adequate training in the application of the HACCP principles; and
3. Compliance with any requirements of national law concerning training programmes for persons working in certain food sectors.
Butchers’ licensing
The Food Safety (General Food Hygiene) (Butchers’Shops) Amendment Regulations 2000
Butchers’ shops selling raw and ready-to-eat food must belicensed
Conditions applicable:Must comply with food safety regulations
All food handlers must be trained in food safety
Must have at least one trained supervisor who canmanage the HACCP system
Effective HACCP, including verification anddocumentation, must be in place
The Food Safety (General Food Hygiene) (Butchers’Shops) Amendment (Scotland) Regulations 2000 Licence condition - all supervisors trained to Intermediatestandard and HACCP system (inc verification anddocumentation) UNLESS there is complete segregation ofall raw meat and unwrapped ready-to-eat food.
Principles of HACCP must be implemented to enablemanagers to avail themselves of a due-diligence defence.
The Meat (Hazard Analysis and Critical ControlPoint) Regulations 2002
Regulations apply to operators of licensed fresh meat and poultry meat:SlaughterhousesCulling plantsCold storesRepackaging centresRewrapping centres
All operators must apply the 7 HACCP principles
The Seven Principles of HACCP (as defined by Codex Alimentarius)
Principle 1 Conduct a hazard analysis
Principle 2 Determine the critical control points (CCPs)
Principle 3 Establish critical limits
Principle 4 Establish a system to monitor control of the CCPs
Principle 5 Establish the corrective action to be taken when monitoringindicates that a particular CCP is not under control
Principle 6 Establish procedures for verification to confirm that the HACCPsystem is working effectively
Principle 7 Establish documentation concerning all procedures andrecords appropriate to these principles and their application
Benefits of HACCP
• HACCP is a structured and systematic approach to identify and control food safety hazards and produce safe food (control on the premises)
• Reduces the risk of food safety incidents (food complaints/food poisoning)
• HACCP demonstrates compliance with the law (also due-diligence defence)
• More cost-effective as it targets resources to the control of critical points and reduces waste,reprocessing and recalls
• Generates a food safety culture/increased confidence that all processes are properly controlled on the premises (customers and enforcers)
• Proactive not reactive (remedial action taken prior to serious problems arising)
• More effective as it is part of the process• Protects brand image
Benefits of HACCP
• Safety can be introduced in product development• All staff involved - can be used as a training exercise• Satisfies customer requirements (retail purchasing
from manufacturers)• Internationally recognised (CODEX)• Demonstrates management commitment to food
safety• Control parameters relatively easy to monitor• More effective than end-product testing (used in
manufacture)• More effective than ad hoc systems of control and
monitoring of all hazards (catering and retailing)• More effective than periodic inspection (all food
businesses)
Role of employees and managers
Individual food handlers have a responsibility for foodsafety.
All food handlers have an involvement with HACCP.
Managers MUST:• Have commitment to implement and maintain
HACCP systems• Ensure a HACCP study is carried out and resources
are available to ensure the HACCP system is implemented and remains effective (people, time,facilities)
• Train staff in food safety/HACCP principles and implementation skills
Employees MUST:• Ensure they follow all food safety instructions• Report when food safety may have been compromised• Comply with food safety law
NB Role of HACCP team members.
Training of all food handlers in relevant aspects ofHACCP is essential for the effective implementation ofHACCP. Specific training will be required to supportthe HACCP plan. Working instructions and proceduresshould be developed for food handlers in relation totheir activities, especially at each critical control point.
MODULE 5
Preparing for implementationOutcomes
The delegate will know and understand how to:
• explain the main elements of a HACCP policy
• explain the steps involved in the implementation of HACCP based on Codex Alimentarius
• explain the need for an experienced and knowledgeable HACCP team and their responsibilities
• identify sources of information available to the HACCP team
• explain the significance of the terms of reference for a HACCP study, including its scope and definition of food safety objectives and methodology
• describe the product/recipe/process
• explain the importance of identifying intended/likely customers
• describe the generic grouping of products
Codex implementation of HACCP (HO20)
Describe the product/recipe/process (2) (HO21)
Stages in the implementation of HACCP(The HACCP study)
1 Assemble and train the HACCP team.(define the terms of reference and the scope)
2 Describe the product/recipe/process.
3 Identify the intended use.
4 Construct a flow diagram and food-room layout showing product, personnel, equipment and waste flows
5 On-site verification of flow diagram and food room layout
6 Identify hazard/risk/severity and control measures.(Hazard analysis)
7 Determine critical control points using the decision tree.
8 Determine critical limits, target levels and tolerances for each critical control point.
9 Establish monitoring system for each CCP.
10 Establish actions to be taken when a CCP is moving out of control, and the corrective actions to be taken if a deviation occurs
11 Establish verification procedures (includes validation and review)
12 Establish record keeping and documentation.
Product type :
Product name:
Important characteristics (aw, pH, preservatives):
How is it intended to be used:
Packaging:
Labelling instructions:
Shelf life:
Intended consumers:
Distribution:
Potential hazards:
Legal requirements:
Approval: Date:
Product descriptionExample of Product Description Form
Product type :
Product name:
Important characteristics (aw, pH, preservatives):
How is it intended to be used:
Packaging:
Labelling instructions:
Shelf life:
Intended consumers:
Distribution:
Potential hazards:
Legal requirements:
Cooked, sliced ham
Porkies Delight
Salt 2.5% to 3.00%Sodium nitrite 100ppm
Ready-to-eat, sliced
Vacuum packed
Store below 5°C, use-by date
25 days if stored below 5°C
All categories, via retail/wholesale
Refrigerated vehicles
Contamination (microbiological,physical, chemical) Multiplication (if not stored under refrigeration)Survival (due to inadequate processing)
Storage below 8°C and labelling requirements
Approval: Date:
Product description
The twelve logical sequence stepsfor the implementation of HACCP(The HACCP study)
Successful implementation of HACCP must be builton good hygiene practice and depends on:
Culture of the organizationManagement commitmentEffective management/supervision (including leadership of the HACCP team)Adequate resources (budget and time)Adequate trainingAccess to scientific informationAccess to necessary expertise
HACCP implementation must be carefully plannedFull implementation - throughout alldepartments/products.
Gradual implementation -department/product at atime.
1. Assemble the HACCP team (multidisciplinaryexpertise - external expertise may be required,especially for smaller businesses). Training willprobably be required. The terms of reference (whichproduct or groups of products/process) and the scopeof the HACCP study (which hazards) should bedetermined.
2. Describe the product/recipe/process. Relevant safetyinformation will include composition, aw, and pH.Processes such as heat-treatment, freezing, brining,and irradiation. Packaging, shelf life, storageconditions and method of distribution.
3. Identify intended use of the product i.e. how will theend user/consumer use the product, e.g. microwavereheating. Awareness of potential abuse, likely timeout of temperature control. Will the product beconsumed by vulnerable groups e.g. babies,immunocompromised or the elderly?
The twelve logical sequence stepsfor the implementation of HACCP(The HACCP study) cont
4. Construct a flow diagram. (It’s also usual to describe theprocess). The flow diagram must cover all steps in theoperation.
5. On-site validation of the flow diagram. - 'walk the line'
6. Identify all potential hazards/risk/severity associatedwith each step, conduct a hazard analysis and considerany measures to control identified hazards (Principle 1).
7. Determine critical control points using the decision tree(Principle 2).
External expertise may be required to support theHACCP team. However, a HACCP plan produced solelyby an external consultant may not result in theessential sense of ownership by managers andoperatives.
Implementation of HACCP (2)
8 Determine critical limits, target levels and tolerancesfor each critical control point. (Principle 3)
9 Establish monitoring system for each CCP. (Principle 4)10 Establish corrective actions to be taken if a deviation
occurs i.e. a CCP is out of control. (Principle 5)11 Establish verification procedures (includes validation
and review). (Principle 6)12 Establish documentation and record keeping.
(Principle 7)
HACCP planThe formal documentation relating to product safety,including:Information on which safety decisions were based:hazards, controls, CCPs, monitoring and correctiveactionCritical limits and targetsFlow diagram(s)HACCP control charts
HACCP should be unique to the specific food operation
Organizations requiring HACCPCustomers )Enforcement officers ) Potential for Accrediting bodies ) contradictionThird parties ) and confusion
Inspectors should be open-minded... the objective is“safe food”
Requirements for inspectorsKnowledgeable in HACCPSkilled inspectorTechnically qualifiedIndustry experience
You can’t overlay HACCP on an unstable system
Assemble and train the HACCPteam
The HACCP team is a group of people with appropriateexpertise who develop and implement the HACCP system. Sizeof team proportionate to size, risk and complexity of thebusiness.
Multidisciplinary - who?
Adequate resources/time and commitment is essentialIdentify team leader and note-taker
Team expertise required for HACCPKnowledge of hazards, risks and controlsHACCP/hazard analysis techniques (hazardidentification, CCP determination, monitoring,verification including sampling)The technology of processFood microbiologyEngineering/equipment used in the processProduct characteristics (aw, pH, composition,preservative)The practical aspects of the operation/process(including consumer target group and abusepotential)Quality assurancePackaging/distributionMaintenance of records/documentationCompetency to inspect/audit
Team responsibilitiesResearch/informationUndertake baseline auditUndertake and record HACCP study CommunicationTraining especially in relation to CCPsVerificationAuditingReview deviations
The role of each team member should be clearlydefined
Sources of information
HACCP team members
Consultants and laboratories
Research organizations (universities)
Public analysts
National food poisoning statistics
Seminars
Codes of practice
Enforcement officers
Food Standards Agency
Health Protection Agency
Trade associations
In-house experts
Mathematical modelling
Customers/suppliers
Customer complaints
Television/radio
TextbooksMagazinesLibrariesInternet
Scientific literature}
Terms of reference
Which hazards?(Micro)biologicalPhysicalChemical (Allergens)
Decide on the scopeWhich operation or process?Which products?Which steps including start and finish?
Describe theproduct/recipe/process
Potential hazards and risksRaw ingredients - (approved supplier)Suitability for bacterial multiplicationComposition/preservative (pH, aw, toxicity)Methods of processing/cooking, storage and distributionIntended shelf lifePackaging and labelling instructionsLegal requirements/standardsAllergies e.g. nutsIntended storage temperaturesWill the product be reheated?Is the reheating essential to destroy microorganisms?Will the food be eaten immediately after reheating?What potential hazards will the food be exposed to? i.e. abuse potential e.g. during transport or by consumer
Identify the intended use/likely customers (where the product will be sold)
Intended consumers/use (vulnerability) (Baby food)Elderly/young/pregnant - Listeria monocytogenesInstitutional feeding, hospitals, homes for the elderly,immune deficiency (ill persons) and drug abusers.Allergen sensitive people.
Generic grouping of foodproducts
Particularly important for catering and retailing
Large variety of products
Limited scientific information
Generic1) HACCP based on each step from delivery through to
service, i.e. steps controlled not product, e.g.refrigerator maintained at 5ºC (Single flow diagram)
2) HACCP of all products subject to similar process, for example
• perishable raw food which is cooked and served hot;• high-risk food which is served cold;• high-risk food (frozen or chilled) which is reheated
and served hot;• perishable raw food which is cooked for hot holding
and then served hot;• perishable raw food which is cooked, cooled and
reheated for hot service;• perishable raw food which is cooked, cooled and
served cold;• frozen raw food which is thawed, cooked and served
hot or cold; and• ambient temperature low-risk foods which are
cooked and served hot or cold.(Several flow diagrams)
3) All products prepared in a similar way grouped, e.g. all items of bread, meat pies, cakes etc.
MODULE 6
Flow diagrams
Course outcomes
The delegate will know and understand how to:
• define a flow diagram
• explain how to construct a flow diagram
• describe the importance of validating the flow diagram
Purchase Approvedsuppliers
Delivery <5ºC
<10 mins
Storage (chilled) 1-4ºC
Preparation (raw) <30 mins
Cook 78ºC
<15 mins
Hot hold/display 63ºC
Serve hot <15 mins
Process led flow diagram for perishableraw food, cooked and served hot or cold
Prepare/garnish
Cool 90 mins
Storage (chilled) 1-4ºC
<15 mins
Display (chilled) 1-4ºC
Serve cold <15 mins
Prepare/garnish
Process description:Chicken and black pepper
Ten, 2 kg frozen chickens and dry black pepper are purchased from approvedsuppliers. The frozen chicken is removed to the large freezers within 10 minutes ofunloading. The freezer operates at -18°C. Each chicken is date marked and used within6 months of purchase. The freezer is alarmed which is activated if the temperature risesabove -15°C for longer than 30 minutes. All freezers are maintained at 6 monthlyintervals.
The black pepper is unloaded into the dry store and stored off the floor on slatted alloyshelves. A pest control contract is in operation and audits are undertaken every 3months.
The frozen chickens are thawed overnight in batches of 10 in a temperature controlledroom at 15°C. After thawing they are refrigerated below 5°C and stored for a maximumof 24 hours until required for cooking.
Cooking takes place in a preheated fan assisted oven at gas mark 4 (180°C) for 2 hours.A disinfected, calibrated probe thermometer is used to ensure the chickens haveachieved a minimum temperature of 75°C. The temperature of the deep thigh muscleis used as the coolest point.
The chickens are cooled rapidly, using a fan which blows air over the chickens whichare loosely covered in tin foil. Chickens are cooled to 7°C within 6 hours and thenstored in the refrigerator at below 5°C.
The chickens are stored for a maximum of two days until required for serving. They aresliced and served within fifteen minutes of removal from the refrigerator. After serving,black pepper is added at the request of a customer immediately prior to consumption.
The group are asked to consider probable hazards at each process step from purchaseto consumption. Controls, targets, critical control points, critical limits, monitoring andfrequency, corrective action and responsibility are to be identified at the relevant timesof the course for each step. At the end of the course each group should havecompleted the HACCP control chart for the sliced cooked chicken and black pepper.
The critical control points should be identified by the groups using the identification ofCCPs chart.
HANDOUTFlow diagram for chicken and black pepper
Slicing/preparation
Cooling
Cooking
Consumption
Addition of black pepper
Serving
Storage (chilled)
Storage (chilled)
Storage (frozen)
Delivery
Thawing
Purchase
Frozen chicken
Storage (dry)
Delivery
Purchase
Black pepper
Construct a flow diagram
Flow diagramA systematic representation of the sequence of steps oroperations involved with a particular food item or process,usually from receipt of raw ingredients to consumer. Mayinclude:Times/temperatures ofprocessing/cooking/cooling/chilling and storage.
It may also be useful to produce a floor plan andlayout which includes:Equipment used etc.Personnel routesProduct routesWaste routesMonitoring points(Toilets, cloakrooms and handwashingfacilities should be highlighted)
The flow diagram and floor plan form an essential partof the HACCP documentation
Walking-the-lineOn-site validation of flow diagram and food roomlayout (at various times of production) to ensure thatwhat you assume happens does happen
potential cross-contaminationfrom delivery toservice}
MODULE 7
Hazard analysis Principle 1: Conduct a hazard analysis
Outcomes
The delegate will know and understand how to:
• define risk and risk assessment
• describe how to conduct hazard analysis
• assess the risk that a hazard may occur
• assess the severity of a hazard
Factors to consider when undertaking hazard analysisRaw ingredients
Are they likely to contain pathogens, toxins, chemical or physical hazards?Likelihood of low-dose pathogens in ready-to-eat food, especially fruit/saladvegetables? Have they been treated to destroy pathogens?
Physical characteristics and composition of ingredients/productInclude:pH, aw, level of preservatives,type of acidCan pathogens multiply and/or survive and produce toxins?Safety record of similar products
Processing/preparationIs there a process step to destroy pathogens, spores and/or toxins?Is contamination after processing likely?
Microbiology of food productIs the food likely to contain pathogens, toxins or spores?Could a change in the microbiological characteristics of food affect its safety?
Premises design (prerequisite)Equipment design (prerequisite)Packaging
Will the packaging protect the food from contamination?Could chemicals leach from the packaging?Does the packaging include essential safety information e.g. relating to allergensor storage temperature and shelf life?
Cleaning and disinfection (prerequisite)Personal hygiene/training (prerequisite)
Storage between packaging and consumptionCould poor storage result in contamination or temperature abuse that could leadto unsafe food?
DistributionCould contamination or multiplication occur?
Intended useIs the food intended to be reheated by the consumer?Is there likely to be food left over, stored and reheated?Potential consumer abuse
Intended consumerIs the food likely to be consumed by someone from a vulnerable group,e.g. the infirm, elderly, immunocompromised or pregnant women?
HANDOUTRisk assessment matrix
Used to assess significant hazards or toensure critical control points are critical
High Risk(1,000)
Low Severity(10)
RxS = 10,000Bone in fish
High Risk (1,000)Med. Severity (100)RxS = 100,000 CCP
Salmonella inundercooked
chicken
High Risk (1,000)High Severity (1,000)
RxS = 1,000,000 CCP
E.coli O157 in under-cooked beefburger
Medium Risk(100)
Low Severity(10)
RxS = 1,000Stone in jam
Medium Risk (100)
Med. Severity(100)
RxS = 10,000Mouse in product
Medium Risk (100)High Severity
(1,000)RxS = 100,000 CCP
Botulism in low-acid food
Low Risk (10)Low Severity (10)
RxS = 100Cardboard in
cooked chickenmeal
Low Risk (10)Med. Severity
(100)RxS = 1,000
Pin in cookedchicken
Low Risk (10)High Severity
(1,000)RxS = 10,000
Razor blade inloaf of bread
LOW SEVERITY HIGH
LOW
RIS
KH
IGH
Hazard analysis
CODEX states that:Hazard analysis involves evaluating information on the hazardsand conditions leading to their presence to decide which aresignificant to food safety and therefore should be addressedby the HACCP plan. This will involve assessing thelikelihood of the hazards (the risk) and the severity of theiradverse effects on health.
Using the flow diagram, all the potential hazards at eachstep should be listed and hazard analysis carried out oneach hazard.
Identify hazards at each step• Presence of contaminants
(including allergens)• Multiplication or survival
of pathogens• Production of toxins• Germination of spores
Factors to consider when undertaking hazard analysis
Raw ingredientsAre they likely to contain pathogens, toxins, chemicalor physical hazards?Likelihood of low-dose pathogens in ready-to-eatfood, especially fruit/salad vegetables? Have they beentreated to destroy pathogens?
Physical characteristics and composition ofingredients/product
Include:pH, aw, level of preservatives,type of acidCan pathogens multiply and/or survive and producetoxins?Safety record of similar products
PREPARATION
COOKING
SERVING
Hazard analysis cont
Processing/preparationIs there a process step to destroy pathogens, sporesand/or toxins?Is contamination after processing likely?
Microbiology of food productIs the food likely to contain pathogens, toxins orspores?Could a change in the microbiological characteristicsof food affect its safety?
Premises design (prerequisite)Equipment design (prerequisite)Packaging
Will the packaging protect the food fromcontamination?Could chemicals leach from the packaging?Does the packaging include essential safetyinformation e.g. relating to allergens or storagetemperature and shelf life?
Cleaning and disinfection (prerequisite)
Personal hygiene/training (prerequisite)
Storage between packaging and consumptionCould poor storage result in contamination ortemperature abuse that could lead to unsafe food?
DistributionCould contamination or multiplication occur?
Intended useIs the food intended to be reheated by the consumer?Is there likely to be food left over, stored andreheated?Potential consumer abuse
Intended consumerIs the food likely to be consumed by someone from avulnerable group,e.g. the infirm, elderly, immunocompromised orpregnant women?
Deciding which hazards aresignificant
RiskThe likelihood that a hazard will occur.
Risk assessmentThe process of identifying hazards, assessing likelihood ofoccurrence and severity, and evaluating the significance(low, medium or high risk).
This involves considering all the relevant availablescientific information to make an informed decisionbased on experienceRequires detailed knowledge of:• Product characteristics• The process • Hazards associated with the product/process
Other information that may be of interest:• Complaint history/experience• Epidemiological information (care - as current
statistics of little value. Very little relevant and accurate information is available. However, website searches for USA and Canada are more productive)
Likelihood of occurrence (sampling results) currentstatistics
Research may be essential
Is the contaminant likely to be in the raw material?Could it survive the process?Could it increase?
SeverityThe magnitude of the hazard or the seriousness of thepossible consequences.Seriousness of symptoms (acute)Likely permanent effects on health (chronic)
Mortality rate ) Especially vulnerable groupsMorbidity rate)
Safety concerns must be separated from qualityconcerns
Scientific information requiredincludes:
• What are the potential hazards/risks?• What temperature/time is needed to destroy
any microbiological hazards that may be present(including toxins)?
• What cooling times are required (risk of spores)?• What concentration of preservative is required to
prevent growth of microorganisms?• What pH and what aw are required to prevent
growth of microorganisms?• What are the risks of contamination/multiplication after
processing?• What risks are there associated with packaging?• What are distribution risks?• What is the shelf life based on specific
storage/distribution temperatures?
Following people may require HACCP:Customers ) Contradiction/confusionThird party ) Different CCPs for differentAccrediting bodies ) customersEnforcers )
MODULE 8
Control measures
Outcomes
The delegate will know and understand how to:
• define control measures
• describe the parameters to which controls can be applied
• suggest measures which effectively control hazards, including generic control measures
Control measures
Control measureAny action or activity that can be used to prevent or eliminatea food safety hazard or reduce it to an acceptable level, i.e.preventing things going wrong.
More than one control measure may be required to controla specific hazard and more than one hazard may becontrolled by a specific control measure.
Controls can be applied to:
• Temperature e.g. refrigerator or cooking• Time especially time at ambient• pH - pathogens won’t normally multiply below a pH
of 4.0. Acids such as vinegar and lemon juice are used to reduce the pH
• Fermentation - involves using acid-producing bacteria to lower the pH e.g. yoghurts and salami
• aw - water activity. Most pathogenic bacteria will not multiply if the aw is below 0•89. Salt and sugar can be used to reduce the aw
• The shape, size or weight. For example, smaller and thinner joints will cool more quickly
• Additives - preservative such as nitrates• Visual assessment - e.g. colour change• Chemical analysis
Generic controls
In catering generic controls are more likely to beapplied successfully.Generic controls may be applied to many products andby many businesses.
keep sources of contamination out of food premises.
(c) Approved suppliers (prerequisite)
(c) (m) (s) Staff vigilance and training (prerequisite)
Training of staffPlanned programme essential - based on legalrequirements, and hazards, controls, monitoring andcorrective action for which they are responsible.
All staff to be trained. Priority for supervisors,managers and high-risk food handlers. Induction, goodhygiene practice/hazards, competency, refresher.
(c) (s) Cleaning and disinfection (prerequisite)
(c) Pest management (prerequisite)
(c) Good personal hygiene (prerequisite)
(c) Waste management (prerequisite)
The class may be able to provide examples of genericcontrols, state which are prerequisites and which typeof hazard is controlled i.e. microbiological, physical andchemical.
Generic controls continued
(m) Stock rotation (prerequisite)
(c) Colour coding (prerequisite)
(c) Good design (prerequisite)
(c) (m) (s) Effective maintenance of premises andequipment (prerequisite)
(c) Well constructed (prerequisite)
(c) Protect/cover
Generic controls continued
(c) Segregation of raw and ready-to-eat foods(prerequisite)
(m) Salt/sugar/acid
(m) Adjust pH
(m) Keep dry
(m) Size, weight and shape of joints
(m) Time management(minimum time at ambient)
(m) Storage temperatures(-18ºC, <5ºC or >63ºC)
(s) Cooking/processing
Physical contamination controls
(c) Inspection belts
(c) Glass policy
(c) Wood policy
(c) Metal detection/magnets
(c) X-rays
In catering, most potential physical and chemicalcontrols are dealt with by prerequisite programmes(personal hygiene/training, cleaning and effective pestcontrol), vigilance, working in an orderly and tidy way,(clean-as-you go), and effective supervision.
The use of branded products and approved suppliersare the most effective controls to prevent purchasingraw ingredients which contain physical or chemicalcontaminants.
Food containers (especially glass jars/bottles)• Use approved supplier - appropriate type and
thickness of glass• Care in transport, unloading and storage• Bottle/jars passing on conveyor belt to filler should
be inverted and blasted with compressed air or water jets
• Protect open jars after 'cleaning' prior to filling• All steps should be routinely monitored• Procedure in place to deal with breakage - especially
during filling• Line should be stopped. Empty jars/bottles should
be checked - inverted/compressed air/waterspray• Product which may have been contaminated - put
on hold• Filler - checked by maintenance/manufacturer• Area thoroughly cleaned• Recall may be necessary if contaminated product
has left site• Report by engineer on action to take to prevent
recurrence• HACCP plan should be reviewed (staff training)
}Manufacture
Chemical contamination controls
(c) Don’t store food in chemical containers
(c) Separation of chemicals from food
(c) Don’t store chemicals in unmarked or food containers
(c) Rinsing following chemical cleaning
Remember - many of these controls are part of the prerequisiteprogrammes. This enables the HACCP plan to concentrate onthe more significant hazards.
MODULE 9
Critical control points Principle 2: Determine the critical control points
Outcomes
The delegate will know and understand how to:
• define critical control point
• identify critical control points, especially by using decision trees such as the codex decision tree
Definitions (2) (HO6)
Codex CCP decision tree (HO27)
Identification of CCPs (2) (HO28)
Group exercise - complete 4th column of HACCPcontrol chart (CCPs) (HO24)
Codex CCP Decision tree
Q1. Do control measures exist?
Q3. Could contamination with identified hazard(s) occur in excess ofacceptable level(s) or increase to unacceptable level(s)?
Q2. Is the step specifically designed to eliminate or reduce the likelyoccurrence of the hazard to an acceptable level?
Q4. Will a subsequent step eliminate the identified hazard(s) or reduce their likely occurrence to an acceptable level?
Q1a. Is control necessary at this step for safety?
Modify step, process or product
STOP*
CRITICALCONTROL
POINT
YES
STOP*
STOP*
YES
NO
YES
NO
NO
NO
NO
YES
YES
*STOP and proceed with the next identified hazard
(at this step or subsequent steps for the identified hazard)
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S Y
OR
NA
S A
PP
RO
PR
IATE
N N N N N Y N N N N N
- - - - - - - - - - -
Pu
rch
ase
of
fro
zen
ch
icke
n
Del
iver
y
Sto
rag
e (f
roze
n)
Thaw
ing
(pre
par
atio
n)
Sto
rag
e (c
hill
ed)
Co
ok
ing
●C
oo
ling
Sto
rag
e (c
hill
ed)
Slic
ing
/pre
par
atio
n
✙Se
rvin
g
Ad
d b
lack
pep
per
* Q
3 h
as b
een
inte
rpre
ted
as
“is
it li
kely
”n
ot
“is
it t
heo
reti
cally
po
ssib
le”.
●If
a r
apid
co
olin
g s
tag
e is
sp
ecif
ical
ly in
tro
du
ced
,e.g
.bla
st c
hill
ing
Q2
co
uld
be
answ
ered
“Y
ES”.
✙Th
e ti
me
is t
oo
sh
ort
to
allo
w t
he
mu
ltip
licat
ion
of
pat
ho
gen
s p
rio
r to
co
nsu
mp
tio
n.I
f th
e h
azar
d a
t se
rvin
g w
as “c
on
tam
inat
ion
wit
h p
ath
og
ens”
,th
is c
ou
ld b
e co
nsi
der
ed a
CC
P
bec
ause
of
low
-do
se p
ath
og
ens
such
as
cam
pyl
ob
acte
r o
r n
oro
viru
s.
Critical control point
A step in the process at which control can be applied andis essential to prevent or eliminate a food safety hazard orreduce it to an acceptable level.
(Control points which are not critical will still requirethe application of GHP (good hygiene practice) or GMP(good manufacturing practice) but, for example,monitoring may be less frequent.
Identification of CCPsKnowledge of team membersScientific informationTrade informationDecision tree
Determination of CCPs is based on risk and severity andwhether or not control measures exist.
Codex HACCP (designed for manufacture) requires the identification of the minimum number ofcritical control points.This ensures resources are concentrated at thesepoints so ensuring a more focused and cost effectivefood safety management system.
Examples of CCPs include cooking and rapid cooling,when this is undertaken to eliminate a hazard orreduce it to a safe level. Product formation may be aCCP e.g. adding acid to reduce pH or sugar to reduceaw. Temperature, pH and salt concentrations arecritical for the growth of starter cultures used infermented products.
Refrigerated storage of high-risk food may beconsidered a CCP although refrigerated storage below5°C may be considered as part of good hygienepractice i.e. part of prerequisites.
Cooling rate for high-risk foods may be critical but inyoghurt pH is the control, not time.
Simplified decision tree
Especially useful for catering and retailing.
If I lose control is it likely that food poisoning/injury/harm will result?
YES
Will a subsequentstep eliminate or
reduce the hazardto an acceptable
level?
CriticalControl
Point(CCP)
Control Point(Good Hygiene
Practice)
NO
YES NO
Decision tree (CODEX) formanufacturer (consistentproduction)
Having identified a hazard at a particular step thefollowing questions may be used to determine if thestep is a CCP.
Q1 Do control measures exist?
Q1a Is control required at this step to ensure food safety?
Q2 Does the step eliminate or reduce the hazard toan acceptable level? Is the step specifically designed to eliminate or reduce the hazard to an accetable level? (Emphasis on the step NOT the control measure at the step)e.g. sterilization of milk, chlorination of water,use of an x-ray machine to detect bones, rapid cooling of cooked meat to prevent spore germination.
Q3 Could contamination occur at unacceptable levels or could it increase to unacceptable levels?('Is it likely?' NOT 'is it theoretically possible')
Q4 Will a subsequent step eliminate or reduce the hazard to an acceptable level?
Identification of CCPsGroups to complete the handout “Identification of CCPs”using chicken and black pepper or an example provided bythe tutor.
Q3 'Could contamination with identified hazards ..... etc.”should be considered as 'is it likely that contamination...etc.' NOT is it theoretically possible that contamination....etc'
Frozen storage: The answer to Q3 is no because the chickenwould have to thaw and rise in temperature above 8ºC for aconsiderable period of time to enable multiplication ofpathogens. If chicken was found thawed and in water itwould be discarded.
Thawing: If the chicken is not completely thawed, forexample, allowing insufficient time, the presence of icewould mean that some pathogens would survive thenormal cooking time. However, because cooking iscontrolled by temperature, i.e. 78ºC not time, then we canrely on the cooking step to destroy any survivingpathogens.
Cooling: If cooling involves leaving the chicken for a fewhours before refrigeration then, arguably this step is not'specifically designed to eliminate or reduce the likelyoccurrence of a hazard to an acceptable level'. However, ifblast chilling was used, specifically to prevent thegermination of spores, then the answer to 'Q2' could be'yes'.
Storage (chilled): The storage between cooking andconsumption is not introduced to eliminate... etc. a hazard.It is the refrigeration/cold temperature not the 'storagestep' that controls the hazard, therefore the answer to 'Q2'is 'NO'.
Serving: The time between removal from the refrigeratorand consumption is too short to allow the multiplication ofpathogens and serving is therefore not a CCP. If there issignificant delay then, arguably, you are introducinganother step i.e. storage prior to serving. This step would
be a CCP and the control measure would be 'temperaturecontrol'.
NB If we had documented evidence of a foodborne illnessresulting from, for example, multiplication during servicethen this knowledge would enable us to reclassify servingas a critical control point.
MODULE 10
Critical limits, target levels and tolerances Principle 3: Establish critical limits
Outcomes
The delegate will know and understand how to:
• define critical limit, target level, tolerance and deviation
• establish critical limits and target levels for CCPs
• provide examples of critical limits and target levels
Generic flow diagram for catering
Refrigerate or cookimmediately when thawed
C PURCHASE OF RAW FOOD
M DELIVERY
M STORAGE
M PREPARATION
CCP CMS COOKING
CCP CM PREPARATION
CCP CM COOLING
CM SERVE COLD
CM SERVE HOT
CHILLED
CCP CM STORAGE CHILLED
CCP CM HOT HOLD & SERVE
CCP CMS REHEAT & SERVE
Check temperatures with a disinfectedelectronic probe thermometer
DRY
FROZEN
M THAWING
CCP CM USE OF LEFTOVERS
CCP CM DISPLAY COLD & SERVE
CM SERVE COLD
Approved suppliers
Time to unload <10 mins
Stock rotation
<1 hour at ambient
<30 mins. at ambient
Stock rotation
<10˚C within 4 hours< 5˚C within 90 minutes (blast chiller)
> 75˚C
< 5˚C< -18˚C
< 5˚C
< -18˚C
<10˚C
< 15 mins
< 15 mins
> 63˚C
< 5˚C
> 75˚C
< 5˚C
PREREQUISITES• Good Hygiene Practices • Pest Control• Cleaning & Disinfection • Personal Hygiene • Waste Management
NB purchase, delivery, chilled storage andpreparation would be CCPs for high-risk foods
CCP = Critical control point
Generic hazardsC = ContaminationM = MultiplicationS = Survival
Critical limits
Critical limitThe value of a monitored action which separates theacceptable from the unacceptable
DeviationFailure to meet a critical limit (corrective action such asdestruction or reprocessing of the product will berequired).
Target levelThe predetermined value for the control measure, whichwill eliminate or control the hazard at a control point.Target levels act as a buffer zone and prevent adeviation by providing a tolerance
ToleranceThe specified degree of latitude for a control measurewhich, if exceeded, requires immediate corrective action.
Establishing critical limitsUsing scientific literature, mathematical modelling,challenge testing, experimentation, expert opinion orregulatory standards and guidelines
Criteria used:Time, temperature, humidity, aw, pH, titratable acidity,preservatives, salt concentration, available chlorine,viscosity (or combination) Must be supported bysound scientific evidence - not dogmaChemical limits - specify maximum levels allowable,e.g. pesticidesPhysical limits, for example, absence of glass.Microbiological limits - usually too slow and productwill be sold before results are available. NB ATP andresazurin test.
Critical limits must be measurable - (does not need tobe continuous but of sufficient frequency to ensurecontrol)observation/test to demonstrate the CCP is undercontrol. May involve more than one factor e.g. timeand temperature (of product and oven).
Critical limits
Critical Target Tolerance Actionlimit Level
Refrigerator 8°C 5°C 3°C (7°C)Cooking 75°C 78°C 3°C (76°C)Temp
If the target level is exceeded action must be taken toprevent loss of control. Action may therefore be takenat 7ºC and 76ºC respectively to ensure the critical limitis not breached.
If the critical limit (or tolerance) is breached immediatecorrective action is necessary to bring the processunder control. The product may need to be destroyedor quarantined pending further testing. (In the case ofcooking if desired temperature not achieved furthercooking usually suffices).
NB variablese.g. Accuracy of thermometer, 1°CTherefore, target levels for refrigerator 4°C, critical limit 7°Cand for cooking 79ºC and 76ºC
+-
MODULE 11
Monitoring Principle 4: Establish a monitoring system
Outcomes
The delegate will know and understand how to:
• define monitoring
• explain the need for monitoring
• explain methods of monitoring CCPs
• explain the requirements of monitoring systems
• explain the knowledge, training and competency of staff with regard to monitoring
Definitions (2) (HO6)
Group exercise - applying HACCP to preparing cooked meat (EX30) (optional)
Group exercise - complete 6th column of HACCPcontrol chart (monitoring) (HO24)
Exercise
Applying HACCP to a potentially unsafe system of preparing cooked meat for a buffet
At 8.30 am in the morning the chef collects 12 large joints of meat from a walk-inrefrigerator.
Using a large trolley he takes the joints to his large 2 metre stainless steelpreparation table sited approximately 50 metres away.
He spends all morning preparing the meat for the buffet and at 12.30 he loadsthe prepared meat onto a protected display.
Any meat not required for the buffet is returned to the walk-in refrigerator.
After two hours on display at ambient temperature any leftover displayed buffetmeat is discarded.
You are required to recommend a safe system of work based on HACCP principlesand to deal specifically with identifying the main hazards, controls and effectivemonitoring.
ExerciseApplying HACCP to a potentially unsafe system of preparing cooked meat for a buffet
A solution
Recognising that the main hazard is likely to be the multiplication of pathogenicbacteria you could suggest that each of the joints should be dealt withseparately. You could specify the maximum time allowed for the preparation ofeach joint which ensures that the temperature of the meat does not exceed 8°Cfor longer than 1 hour. A disinfected probe thermometer may be used to monitorthe effectiveness of the system and all measurements recorded.
Unfortunately the amount of additional walking and monitoring involved meansthat the chef has inadequate time to complete the job. This means this “safe”system is unlikely to be adhered to at all times and an unnecessary food safetyrisk arises.
A better solution would be to reduce the 2 metre table to one metre, so he onlyhas room for one joint at a time, and to provide a refrigerator under or adjacentto the table. This will mean that the meat can be collected from the walk-in chillerand placed in the mis-en-place refrigerator. Only one joint at a time will be takenfrom the refrigerator. After slicing and preparation there is no room on the tableso it has to be put back in the refrigerator and another joint selected.
The system itself involves very little additional work other than monitoring thetemperature of the mis-en-place refrigerator. This could be done automatically,with an alarm fitted to warn of unacceptable temperatures.
The solution recommended has ensured that the easy way of working is the safeway. Imposing onerous controls and monitoring on a system which is difficult orrequires significantly more work is much less likely to be successful. A breakdownis particularly likely if the operation is under pressure, e.g. because of shortage ofstaff.
The buffet display is dealt with as previously but is safer as the meat is atrefrigeration temperature when first displayed. A refrigerated display would bepreferable but as the display is only for two hours the meat could be returned tothe refrigerator for other use (NOT displayed again)
Monitoring
MonitoringThe planned observations and measurements of controlparameters to confirm the process is under control andcritical limits are not exceeded.
Monitoring is required to:Confirm that a CCP is under controlEnsure target levels are not breached. This enablesaction to be taken when a trend towards a loss ofcontrol is identifiedIdentify deviations and trigger corrective actionsProvide records:
For verificationTo identify reasons for complaintsFor due diligence
Monitoring must permit rapid detection and correction
Monitoring may be manual or automatic, continuous or atset frequencies
Frequency of monitoring must be relevant to theprocess and the product throughout. The correctiveaction to be taken will also determine frequency.
Continuous on-line (automatic) is preferable e.g.thermographs.
Must ensure samples are statistically representativeAccuracy essential - staff trained to use equipmentEquipment must be calibrated as recommended by themanufacturer.
Monitoring records must be checked by asupervisor/manager - may be daily, weekly or monthly.
Types of monitoring
Usually physical or chemicalAuditsVisual inspection (premises, vehicle, practices)Measuring e.g. temperature, pH, aw, times etc.Competency checksOrganoleptic (smell, observation and touch)Checking documentation/records
AuditsPremises, procedures, practicesCleaning system/equipmentElectric fly killers
Checking recordsGoods receipt bookCustomer complaintsTemperature control/cookingDate codes/stock rotationTraining/sicknessCleaning schedulesSampling/test resultsPest control bookCalibration of instrumentsMaintenance/servicingInspection/audit forms
Monitoring of trends e.g. gradual increase in fridgetemperatures or increasing bacterial loading are mostuseful to enable action to be taken to prevent a deviation.
Staff must be competent to deal with all potentialproblems and the action they are authorised to take.
Calibration of thermometers
Certification that equipment e.g.thermometers areaccurate. Carried out against certified equipment,traceable to nationally recognised standards.
On-site calibration - using boiling water (100ºC) andwater/crushed ice (0ºC) may be undertakenweekly/monthly - for thermocouples and thermistors.
Monitoring systems
Should state:
What - the critical limits, the target levels andtolerances.
How - details of how the monitoring should beundertaken (equipment and calibration should bespecified). Written procedures useful
Where - where the monitoring should be undertaken(at the CCP or as close as possible to the CCP)
Monitoring may be:on line, e.g. time/temperature off line, e.g. salt or pH
Who - is responsible for the monitoring (include training requirements) and, if necessary,checking that monitoring has been carried outsatisfactorily.
When - when the monitoring should be undertakenincluding continuous or batch.The monitoring intervalmust be frequent enough to ensure that the hazard iscontrolled - without requiring significant destructionof product.
Microbiological testingIn some cases may be required for manufacturing.Furthermore as rapid techniques are developed - willbe a more useful tool. However, the number of samplesrequired to reliably detect low levels of pathogens isunacceptably high and not cost-effective.
Not practical for catering/retailing - for monitoringunder usual circumstances.
Microbiological testing by laboratories is useful forverification purposes.
Staff must be trained to monitor critical control points and shouldhave:
• Knowledge of HACCP
• Knowledge of importance of critical control pointsand monitoring
• Knowledge of frequency of monitoring
• Knowledge of target levels/critical limits
• Competency to monitor and record
• Competency to take corrective action
Module 12
Corrective actions Principle 5: Establish the corrective action to be takenwhen monitoring indicates that a particular CCP isnot under control
Outcomes
The delegate will know and understand how to:
• define corrective deviation and action
• explain the need for corrective action when a critical limit is breached
• explain the formulation and implementation of corrective action
• explain how to deal with product subject to deviation
• explain the need for traceability and recall
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Ap
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ct l
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haz
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nts
e.g
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Pu
rch
ase
of:
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zen
,ra
wch
icke
n
Bla
ckp
epp
er
Co
nta
min
ated
pro
du
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Co
nta
min
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pro
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ct(m
icro
bio
log
ical
(sp
ore
s) p
hys
ical
an
d c
hem
ical
)N
B S
alm
on
ella
An
nu
al a
ud
it (Q
C)
Ref
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fro
msa
tisf
ied
cu
sto
mer
sO
bta
in r
elev
ant
do
cum
enta
tio
n e
.g.
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P p
lan
Sam
plin
gA
bse
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of
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sto
mer
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His
tori
cal c
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nd
eliv
erie
s
P P
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ritt
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stru
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wri
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(pro
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ct a
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on
to
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e C
CP
un
der
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l)*
Un
load
an
d p
lace
in f
reez
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ith
in 1
0 m
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Spec
ify
del
iver
yre
qu
irem
ents
,esp
ecia
llyte
mp
erat
ure
co
ntr
ol
Six
mo
nth
max
imu
m s
hel
flif
e at
–1
8ºC
Spec
ific
atio
n
Del
iver
yo
f:
Fro
zen
chic
ken
Bla
ckp
epp
er
Mu
ltip
licat
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of
pat
ho
gen
s b
ecau
seo
f th
e d
eliv
ery
of
thaw
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rod
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Un
sati
sfac
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hic
le
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d o
uts
ide
dat
e co
de
Del
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fco
nta
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hys
ical
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r ch
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h t
ime)
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tem
per
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Ch
eck
tim
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un
load
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Mo
nth
ly a
ud
its
(M)
Ch
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del
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)
Ch
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dat
e co
de
(F)
N P N
Rej
ect
un
sati
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tory
del
iver
ies
(ab
ove
–1
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) or
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t-o
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f:
Bla
ckp
epp
erK
eep
dry
an
d w
ell v
enti
late
d
Inte
gra
ted
pes
t m
anag
emen
t
Mo
nth
ly a
ud
its
(M)
Vis
ual
ob
serv
atio
n b
yfo
od
han
dle
r u
sin
g t
he
sto
re (d
aily
)2
mo
nth
ly a
ud
it b
yp
est
con
tro
l op
erat
or
Rep
air
sto
re (S
)D
isca
rd c
on
tam
inat
edp
rod
uct
(S)
Cal
l in
pes
t co
ntr
ol o
per
ato
r(S
)
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
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......
.....
......
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pro
ved
by:
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e ...
......
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f ...
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do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
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l des
ign
ed a
nd
mai
nta
ined
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ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
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dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
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Qu
alit
y co
ntr
ol
Sto
rag
e o
f:
Fro
zen
chic
ken
Sto
re a
t co
rrec
t te
mp
erat
ure
(-
18
°C)
Ala
rmed
un
its
Sto
rag
e at
tem
per
atu
res
wh
ich
resu
lt in
sp
oila
ge,
mo
uld
gro
wth
or
mu
ltip
licat
ion
of
foo
d p
ois
on
ing
bac
teri
a
Ch
eck
and
rec
ord
tem
per
atu
re o
f fr
eeze
rd
aily
:tar
get
-18
°C (F
)C
hec
k te
mp
.rec
ord
sw
eekl
y(S)
Ad
vise
ap
pro
pri
ate
sup
ervi
sor
of
any
pro
ble
m (F
)
NC
hic
ken
bel
ow
–1
2ºC
,ret
urn
to
–18
ºC.(
F)
Fro
zen
ch
icke
n a
bo
ve –
12
ºC.
com
ple
te t
haw
ing
,co
ok
and
serv
e.(S
)R
emo
ve a
nd
des
tro
y th
awed
chic
ken.
(S)
Cal
l in
mai
nte
nan
ceen
gin
eer/
rep
lace
fre
ezer
.(S)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
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pro
ved
by:
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e ...
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f ...
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do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
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per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
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Qu
alit
y co
ntr
ol
Thaw
ing
of:
Ch
icke
nC
on
tro
lled
th
awin
g b
etw
een
10
°C a
nd
15
°C f
or
12
ho
urs
or
ath
awin
g c
abin
et
Pla
ce in
ref
rig
erat
or
or
coo
kim
med
iate
ly a
fter
th
awin
g
Failu
re t
o t
haw
Mu
ltip
licat
ion
of
salm
on
ella
bec
ause
of
thaw
ed f
oo
d le
ftat
am
bie
nt
tem
per
atu
re
Ch
eck
plia
ble
,fre
e o
fic
e an
d c
hec
kte
mp
erat
ure
bef
ore
coo
kin
g (e
ach
ch
icke
n)
(F)
N+ N
Ab
sen
ce o
fic
eC
on
tin
ue
thaw
ing
(F)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
+Th
is is
no
t a
crit
ical
co
ntr
ol p
oin
t if
you
are
usi
ng
a c
alib
rate
d d
igit
al t
her
mo
met
er to
en
sure
th
e cr
itic
al c
oo
kin
g t
emp
erat
ure
of 7
5°C
has
bee
n a
chie
ved
.H
ow
ever
,if y
ou
are
rel
yin
g o
n a
tim
e o
nly
to
co
ntr
ol c
ooki
ng
it w
ou
ld b
e a
crit
ical
co
ntr
ol p
oin
t as
th
e n
orm
al c
oo
kin
g t
ime
wo
uld
no
t b
e ad
equ
ate
toen
sure
saf
e ce
ntr
e te
mp
erat
ure
s h
ave
bee
n a
chie
ved,
if th
e ch
icke
n h
ad n
ot
com
ple
tely
th
awed
.
This
do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
Ad
just
th
erm
ost
at (S
)C
all i
n m
ain
ten
ance
(S)
Mo
ve c
hic
ken
to
an
oth
erre
frig
erat
or
(F)
Use
imm
edia
tely
(S)
Des
tro
y (S
)
Rem
ove
an
d d
estr
oy
ou
t-o
f-d
ate
chic
ken
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
Sto
rag
eo
f:
Thaw
edch
icke
nSt
ora
ge
at c
orr
ect
tem
per
atu
reTa
rget
<5
ºCA
larm
ed u
nit
s
Ap
ply
dat
e co
de
(24
ho
urs
)
Mu
ltip
licat
ion
of
foo
d p
ois
on
ing
bac
teri
a b
ecau
se o
fst
ora
ge
at h
igh
tem
per
atu
re(a
bo
ve 8
ºC)
Ch
eck
reg
ula
rly
and
reco
rd t
emp
erat
ure
2
x d
aily
(F)
Mo
nth
ly a
ud
it(M
)
Ch
eck
dat
e co
de(
F)
N N
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
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e ...
......
......
....o
f ...
......
......
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do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
Co
ok
ing
of:
Ch
icke
nTh
oro
ug
h c
oo
kin
g >
78
ºCJu
ices
of
mea
t to
ru
n c
lear
Ensu
re f
roze
n p
ou
ltry
com
ple
tely
th
awed
Surv
ival
of
pat
ho
gen
sC
hec
k t
emp
erat
ure
of
chic
ken
in c
old
est
par
to
f o
ven
wit
hca
libra
ted
dis
infe
cted
ther
mo
met
ers
(eve
ryb
atch
) (F)
Vis
ual
ch
eck
of
coo
ked
chic
ken
(F)
Mo
nth
ly a
ud
it (M
)
Y7
5°C
Co
nti
nu
e co
ok
ing
un
til c
ore
tem
per
atu
re o
f 7
8°C
ach
ieve
d(F
) Ex
ten
d f
utu
re c
oo
kin
g t
imes
(QC
)C
arry
ou
t co
ok
ing
tri
als
too
bta
in m
ore
info
rmat
ion
(QC
)C
all i
n m
ain
ten
ance
bec
ause
of
def
ecti
ve o
ven
(S)
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
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do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
Co
olin
go
f:
Ch
icke
nC
oo
l rap
idly
fro
m 6
0°C
to
21
°Cin
<2
ho
urs
an
d f
rom
21
°C t
o 7
°C in
<4
ho
urs
(FD
A o
fU
SA S
tan
dar
d)
Co
ol c
hic
ken
s in
des
ign
ated
area
pro
tect
ed f
rom
con
tam
inat
ion
Ger
min
atio
n o
fsp
ore
s an
dm
ult
iplic
atio
n o
ffo
od
po
iso
nin
gb
acte
ria
Co
nta
min
atio
n
Ch
eck
and
rec
ord
tim
ean
d t
emp
erat
ure
of
coo
ling
of
each
bat
chw
ith
a d
isin
fect
edp
rob
e th
erm
om
eter
(F)
Mo
nth
ly a
ud
it(M
)
Y P
2.5
ho
urs
to
coo
l bel
ow
21
ºC a
nd
5h
ou
rs t
oco
ol b
elo
w7
°C
Qu
aran
tin
e ch
icke
ns
inre
frig
erat
or
for
con
sid
erat
ion
by
(QC
)R
edu
ce s
ize
or
wei
gh
t o
f b
ird
(M)
Car
ry o
ut
coo
ling
tri
als
too
bta
in m
ore
info
rmat
ion
(QC
)P
urc
has
e a
bla
st c
hill
er (M
)
This
do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
Ad
just
th
erm
ost
at (S
)C
all i
n m
ain
ten
ance
(S)
Mo
ve c
hic
ken
to
an
oth
erre
frig
erat
or
(F)
Use
imm
edia
tely
(S)
Des
tro
y (S
)
Rem
ove
an
d d
estr
oy
ou
t-o
f-d
ate
chic
ken
(S)
Rem
ove
an
d d
estr
oy
con
tam
inat
ed f
oo
d (S
)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
Sto
rag
eo
f:
Co
oke
dch
icke
nSt
ora
ge
at c
orr
ect
tem
per
atu
reTa
rget
<5
ºCA
larm
ed u
nit
s
Ap
ply
dat
e co
de
(24
ho
urs
)
Seg
reg
atio
n f
rom
raw
fo
od
Mu
ltip
licat
ion
of
foo
d p
ois
on
ing
bac
teri
a b
ecau
se o
fst
ora
ge
at h
igh
tem
per
atu
re(a
bo
ve 8
ºC)
Co
nta
min
atio
n
Ch
eck
reg
ula
rly
and
reco
rd t
emp
erat
ure
2
x d
aily
(F)
Mo
nth
ly a
ud
it(M
)
Ch
eck
dat
e co
de(
F)
Ch
eck
wh
en u
sin
gre
frig
erat
or(
F)
Y Y P?
8°C
(2h
ou
rs)
48
ho
urs
Ab
sen
ce o
fco
nta
ctw
ith
raw
pro
du
ct
This
do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
Slic
ing
of:
Ch
illed
coo
ked
chic
ken
Go
od
per
son
alh
ygie
ne/
trai
nin
gC
lean
an
d d
isin
fect
kn
ife
and
foo
d-c
on
tact
su
rfac
esC
olo
ur
cod
ing
Dis
po
sab
le w
ipin
g c
loth
Sep
arat
e fr
om
raw
Ch
icke
n t
o b
e sl
iced
wit
hin
30
min
s o
f co
olin
g
On
ly o
ne
chic
ken
to
be
slic
edat
a t
ime
Co
nta
min
atio
n
Mu
ltip
licat
ion
of
salm
on
ella
if le
ft a
tam
bie
nt
for
too
lon
g
Pro
fici
ency
tes
tin
g (6
mo
nth
ly) (
S)C
hec
k cl
ean
ing
sch
edu
le (d
aily
)(F)
Swab
bin
g s
urf
aces
and
eq
uip
men
t(w
eek
ly)(
QC
)M
on
thly
au
dit
(M)
Ch
eck
and
rec
ord
tim
es a
nd
tem
per
atu
res(
F)
P Y
8°C
(1
ho
ur)
Dis
card
co
nta
min
ated
pro
du
ct(S
)R
etra
inin
g/i
nst
ruct
ion
Mo
re e
ffec
tive
su
per
visi
on
Pro
vid
e a
tem
per
atu
reco
ntr
olle
d s
licin
g r
oo
m (M
)
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
Issu
e n
ew in
stru
ctio
ns
(M)
Ret
rain
ing
Imp
rove
su
per
visi
on
Rej
ect
and
des
tro
yco
nta
min
ated
pro
du
ct (S
)R
etra
in/n
ew in
stru
ctio
ns
Imp
rove
d s
up
ervi
sio
n
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/PC
RIT
ICA
LLI
MIT
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
Serv
ing
of:
Ch
icke
n
Ap
ply
bla
ckp
epp
er
Kee
p c
hick
en re
frig
erat
edu
nti
l req
uir
ed fo
r im
med
iate
serv
ing
Serv
e w
ith
in 1
5 m
inu
tes
of
rem
ova
l fro
m r
efri
ger
ato
r
Hig
h s
tan
dar
ds
of
per
son
alh
ygie
ne
and
tra
inin
gA
ll u
ten
sils
an
d c
rock
ery
clea
ned
an
d d
isin
fect
ed
Ad
d ju
st b
efo
reco
nsu
mp
tio
n
Mu
ltip
licat
ion
of
pat
ho
gen
s b
ecau
seo
f p
rolo
ng
ed t
ime
at a
mb
ien
t
Co
nta
min
atio
nfr
om
eq
uip
men
t/w
aite
rs
Ger
min
atio
n o
fsp
ore
s
Ch
eck
tim
e d
aily
(S)
Mo
nth
ly a
ud
its(
M)
N+ P N
MO
NIT
OR
ING
an
dTA
RG
ETS
(IN
CLU
DE
FREQ
UEN
CY
)
This
do
es n
ot
incl
ud
e th
e o
nly
,or
all,
the
answ
ers
it is
inte
nd
ed a
s a
gu
ide
on
lyP
= p
rere
qu
isit
es -
app
rove
d s
up
plie
r,p
rem
ises
an
d e
qu
ipm
ent
wel
l des
ign
ed a
nd
mai
nta
ined
,sta
ff t
rain
ed a
nd
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
+
Ser
vin
g is
no
t co
nsi
der
ed a
CC
P,as
reg
ard
s m
ult
iplic
atio
n,a
s th
ere
is in
suff
icie
nt
tim
e b
etw
een
rem
oval
fro
m t
he
refr
iger
ato
r an
d c
on
sum
pti
on
.If t
her
e w
as a
sig
nifi
can
t d
elay
th
is w
ou
ld in
eff
ect
be
intr
od
uci
ng
ano
ther
ste
p p
rio
r to
ser
vin
g.Th
is w
ou
ld b
e a
CC
P an
d t
he
con
tro
l wo
uld
be
'tem
per
atu
re c
on
tro
l'.
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
Purc
has
e o
f raw
mat
eria
ls(c
ho
ice
of
sup
plie
r)
Sele
ct le
ast
haz
ard
ou
s in
gre
die
nts
On
ly u
se r
epu
tab
le s
up
plie
rs (a
pp
rove
dsu
pp
liers
’lis
t)
Spec
ifica
tio
n fo
r p
rod
uct
saf
ety,
incl
ud
ing
del
iver
y te
mp
erat
ure
s
Foo
d p
rod
uct
is li
kely
to
be
con
tam
inat
ed w
ith
pat
ho
gen
s,to
xin
s,sp
oila
ge
org
anis
ms,
chem
ical
s o
rfo
reig
n b
od
ies
Au
dit
su
pp
liers
’pre
mis
es (r
eco
rdd
etai
ls) a
nn
ual
ly (Q
C)
Ob
tain
do
cum
enta
tio
n t
od
emo
nst
rate
th
ey fo
llow
go
od
hyg
ien
e p
ract
ice,
e.g.
foo
d s
afet
yp
olic
y,H
AC
CP
do
cum
enta
tio
n,
rep
ort
fro
m t
hir
d p
arty
au
dit
or,
com
ple
ted
hyg
ien
eq
ues
tio
nn
aire
(QC
)
Ob
tain
ref
eren
ces
fro
m o
ther
sati
sfie
d c
ust
om
ers
(QC
)
Ab
sen
ce o
f cu
sto
mer
co
mp
lain
ts(o
n-g
oin
g) (
QC
)
Sam
plin
g o
f pro
du
ct (r
etai
nre
cord
s) (Q
C)
His
tori
cal c
hec
k o
f del
iver
ies
(QC
)
PRe
visi
t/in
spec
t su
pp
lier
(QC
)
Revi
ew p
rod
uct
sp
ecifi
cati
on
(QC
)
Avo
id/r
epla
ce u
nsa
tisf
acto
ry s
up
plie
rs (M
)
Pro
vid
e w
ritt
en in
stru
ctio
ns
of e
xpec
ted
stan
dar
ds
and
/or
reaf
firm
ing
sp
ecifi
cati
on
(QC
)
Sen
d w
arn
ing
lett
er s
tati
ng
co
nse
qu
ence
so
f fai
lure
to
mee
t st
and
ard
s (M
)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
Del
iver
y o
f raw
mat
eria
ls (h
igh
-ri
sk fo
od
s,d
ryfo
od
s,fr
ozen
foo
ds,
raw
foo
ds
wh
ich
may
con
tain
pat
ho
gen
s,ra
wfo
od
s w
hic
h a
reu
nlik
ely
toco
nta
inp
ath
og
ens)
Raw
an
d h
igh
-ris
k fo
od
co
mp
lete
ly s
epar
ate
Spec
ify d
eliv
ery
req
uir
emen
ts in
clu
din
gp
acka
gin
g r
equ
irem
ents
Sep
arat
e d
ebox
ing
are
a
Targ
et t
emp
<5º
C
Targ
et t
emp
-18º
C
Min
imis
e ti
me
for
un
load
ing
Staf
f tra
inin
g
Del
iver
y o
f co
nta
min
ated
foo
d e
.g.r
aw a
nd
hig
h-r
isk
foo
d d
eliv
ered
to
get
her
Del
iver
y o
f fo
od
fro
mu
nap
pro
ved
so
urc
es
Op
en fo
od
exp
ose
d t
o d
ust
,b
ird
s,p
hys
ical
co
nta
min
ants
Dam
aged
pac
kag
ing
Un
sati
sfac
tory
del
iver
yve
hic
le/d
rive
r
Co
nta
min
atio
n r
esu
ltin
g fr
om
deb
oxin
g/u
np
acki
ng
Foo
d o
uts
ide
its
‘use
-by’
dat
e
Hig
h-r
isk
foo
d >
8°C
Froz
en fo
od
wh
ich
is t
haw
ing
The
gro
wth
of f
oo
d p
ois
on
ing
bac
teri
a/to
xin
pro
du
ctio
nd
ue
to p
rolo
ng
ed d
elay
s af
ter
un
load
ing
Ch
eck
each
del
iver
y ag
ain
stap
pro
ved
su
pp
lier
list
(F)
Ch
eck
con
dit
ion
of e
ach
del
iver
y,in
clu
din
g p
acka
gin
g (F
)
Vis
ual
ap
pea
ran
ce/f
itn
ess
of
foo
d a
nd
ab
sen
ce o
f pes
ts,e
tc.
(F)
Ch
eck
co
nd
itio
n,c
lean
lines
s o
fea
ch d
eliv
ery
veh
icle
,an
d d
rive
r(F
)
Mo
nth
ly a
ud
it (S
)
Ch
eck
dat
e co
des
(F)
Ch
eck/
reco
rd t
emp
of h
igh
-ris
kan
d fr
ozen
foo
d (a
s p
er s
pec
) (F)
,
Reco
rd t
ime
of d
eliv
erie
s an
dti
me
into
sto
rag
e (F
)
Ch
eck
tem
p/t
ime
reco
rds
(S)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Co
mp
eten
cy t
esti
ng
(S)
P Y
Ab
sen
ce o
fco
nta
min
atio
n
8°C
Reje
ct c
on
tam
inat
ed/u
nfit
foo
d e
.g.b
low
nca
ns,
bad
ly d
amag
ed p
acka
gin
g,ev
iden
ceo
f pes
ts,e
vid
ence
of t
haw
ing
of f
roze
nfo
od
s (F
)
Reje
cts
mu
st b
e re
po
rted
to
ap
pro
pri
ate
man
ager
s fo
r fu
rth
er a
ctio
n e
.g.r
e-o
rder
,n
ew in
stru
ctio
ns
to s
up
plie
r o
r ch
ang
ing
sup
plie
r
Reje
ct o
ut-
of-
dat
e fo
od
(F)
Reje
ct d
eliv
erie
s o
f hig
h-r
isk
foo
d a
bo
vesp
ecifi
ed t
emp
erat
ure
s e.
g.ab
ove
8°C
or
abo
ve -
15°C
if fr
ozen
(S)
Rein
stru
ct/r
etra
in (S
)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
Sto
rag
e (c
hill
ed)
Ensu
re s
atis
fact
ory
pac
kag
ing,
wra
pp
ing,
pro
tect
ion
,co
nta
iner
s
Sep
arat
e ra
w a
nd
hig
h-r
isk
foo
ds
Sto
ck r
ota
tio
n,d
ate
cod
es
Sto
re a
t co
rrec
t te
mp
erat
ure
(tar
get
tem
p<
5ºC
)
Ala
rmed
un
its
Staf
f tra
inin
g
Co
nta
min
atio
n o
f hig
h-r
isk
foo
d fr
om
raw
foo
d,ch
emic
als
or
fore
ign
bo
die
s
Foo
d o
uts
ide
its
use
-by
dat
e
Mu
ltip
licat
ion
of f
oo
dp
ois
on
ing
bac
teri
a/to
xin
pro
du
ctio
n d
ue
to s
tora
ge
abo
ve 5
°C
Mu
ltip
licat
ion
of f
oo
dsp
oila
ge
org
anis
ms
du
e to
pro
lon
ged
sto
rag
e
Sto
rag
e o
f fo
od
in o
pen
can
s
Ch
eck
corr
ect
sto
rag
e o
f hig
h-
risk
an
d r
aw fo
od
s w
hen
ch
iller
is u
sed
(F)
Ch
eck
pac
kag
ing
dai
ly (F
)
Mo
nth
ly h
ygie
ne
aud
it (S
)
Ch
eck
foo
d c
om
pla
int
reco
rds
wee
kly
(S)
Ch
eck
dat
e co
des
dai
ly a
nd
reco
rd o
bse
rvat
ion
s (F
)
Ch
eck
tem
per
atu
re o
f fo
od
inch
iller
th
rou
gh
ou
t d
ay,.
Reco
rd(F
)
Ch
eck
tem
per
atu
re/d
ate
cod
ere
cord
s w
eekl
y (S
)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Co
mp
eten
cy t
esti
ng
(on
-go
ing
)(S
)
P Y
Ab
sen
ce o
fco
nta
min
atio
n
8°C
fo
r 2
ho
urs
Rem
ove
/des
tro
y u
nsa
tisf
acto
ry,
con
tam
inat
ed fo
od
(S)
Reje
ct o
ut-
of-
dat
e fo
od
(F)
Rem
ove
/des
tro
y o
ut-
of-
dat
e fo
od
(S)
Ad
just
th
erm
ost
at/c
all i
n m
ain
ten
ance
op
erat
or
(S)
Arr
ang
e fo
r ad
dit
ion
al c
hill
er/c
hill
erca
pac
ity
(M)
Use
foo
d im
med
iate
ly (S
)
Rep
air/
rep
lace
eq
uip
men
t (M
)
Rein
stru
ct/r
etra
in s
taff
(S)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
Sto
rag
e (f
roze
n)
Sep
arat
e h
igh
-ris
k/ra
w fo
od
Sto
re a
t co
rrec
t te
mp
erat
ure
(-
18°C
)
Ala
rmed
un
its
Staf
f tra
inin
g
Co
nta
min
atio
n o
f hig
h-r
isk
foo
d
Sto
rag
e at
tem
per
atu
res
wh
ich
res
ult
in s
po
ilag
e,m
ou
ld g
row
th o
rm
ult
iplic
atio
n o
f fo
od
po
iso
nin
g b
acte
ria
Bac
teri
al g
row
th in
th
awed
foo
ds
Ch
eck
for
sati
sfac
tory
pac
kag
ing
/sto
rag
e (F
)
Mo
nth
ly h
ygie
ne
aud
it (S
)
Ch
eck
foo
d c
om
pla
int
reco
rds
mo
nth
ly (S
)
Ch
eck
and
rec
ord
tem
per
atu
reo
f fre
ezer
dai
ly (
F)
Ch
eck
tem
per
atu
re r
eco
rds
wee
kly
(S)
Ad
vise
ap
pro
pri
ate
sup
ervi
sor
of
any
pro
ble
m (F
)
Co
mp
eten
cy t
esti
ng
(on
-go
ing
)(S
)
P N
Rem
ove
an
d d
estr
oy
con
tam
inat
ed fo
od
(S)
Foo
d b
etw
een
-5°
C a
nd
-12
°C,c
om
ple
teth
awin
g,co
ok
and
ser
ve (S
)
Rem
ove
an
d d
estr
oy
hig
h-r
isk
thaw
ed fo
od
(S)
Cal
l in
mai
nte
nan
ce e
ng
inee
r/re
pla
cefr
eeze
r (S
)
Rein
stru
ct/r
etra
in s
taff
(S)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
Prep
arat
ion
(co
nta
min
atio
nh
azar
ds)
Effe
ctiv
e d
esig
n,u
nid
irec
tio
nal
wo
rkflo
w,
sep
arat
ion
of r
aw a
nd
hig
h-r
isk
pre
par
atio
nar
eas
Sep
arat
e u
ten
sils
an
d e
qu
ipm
ent
for
raw
and
hig
h-r
isk
foo
ds
(co
lou
r co
din
g)
Diff
eren
t st
aff f
or
raw
an
d h
igh
-ris
k fo
od
s
Min
imis
e ti
me
foo
d is
at
roo
m t
emp
erat
ure
(Tar
get
:max
imu
m a
bo
ve 8
ºC 3
0 m
ins)
Prep
are
min
imu
m a
mo
un
t o
f fo
od
Sati
sfac
tory
su
rfac
es a
nd
eq
uip
men
t
Staf
f tra
inin
g
Co
nta
min
atio
n o
f hig
h-r
isk
foo
d fr
om
raw
foo
d (d
irec
t o
rin
dir
ect)
Co
nta
min
atio
n fr
om
con
tam
inat
ed w
ork
surf
aces
/ute
nsi
ls
Co
nta
min
atio
n fr
om
wip
ing
clo
ths
Co
nta
min
atio
n fr
om
pes
ts,
esp
ecia
lly fl
yin
g in
sect
s
Mu
ltip
licat
ion
of f
oo
dp
ois
on
ing
bac
teri
a/to
xin
pro
du
ctio
n d
ue
to p
rolo
ng
edti
me
at a
mb
ien
t
Co
nta
min
atio
n fr
om
chem
ical
s,e.
g.fly
sp
ray
Co
nta
min
atio
n fr
om
fore
ign
bo
die
s,e.
g.b
oxes
un
pac
ked
adja
cen
t to
pre
par
atio
n a
reas
Flak
ing
pai
nt
on
wal
ls a
nd
ceili
ng
Rust
y,p
itte
d d
efec
tive
equ
ipm
ent/
ute
nsi
ls
Mo
nth
ly h
ygie
ne
aud
it (S
)
Wee
kly
bac
teri
olo
gic
alsw
abb
ing
of s
urf
aces
(ATP
) (S)
Ch
eck
tim
es a
t am
bie
nt
tem
per
atu
res
- rec
ord
info
rmat
ion
(F)
Ch
eck
reco
rds
wee
kly
(S)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Peri
od
ic c
om
pet
ency
tes
tin
g o
ffo
od
han
dle
rs (S
)
P Y
Ab
sen
ce o
fco
nta
min
atio
n
1 h
ou
r ab
ove
8°C
Re-d
esig
n p
rem
ises
(M)
Ch
ang
e ra
w m
ater
ials
e.g
.use
co
oke
dch
icke
n in
stea
d o
f raw
(QC
)
Rem
ove
an
d d
estr
oy
con
tam
inat
ed o
rp
ote
nti
ally
un
safe
foo
d (S
)
Use
imm
edia
tely
or
des
tro
y an
y h
igh
-ris
kfo
od
ab
ove
8°C
for
2 h
ou
rs
Issu
e n
ew in
stru
ctio
ns
or
retr
ain
foo
dh
and
lers
(S)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
Sto
rag
e (d
ry)
Pest
co
ntr
ol,
pes
t-p
roo
f co
nta
iner
s,g
oo
dh
ou
seke
epin
g,st
ore
off
flo
or
(tar
get
-ab
sen
ce o
f pes
ts)
Car
e w
ith
deb
oxin
g/o
pen
ing
to
avo
idfo
reig
n b
od
y co
nta
min
atio
n
Kee
p d
ry/w
ell v
enti
late
d
Sto
ck r
ota
tio
n
Sto
re o
ut
of l
igh
t
Sep
arat
e st
ora
ge
for
clea
nin
g c
hem
ical
s et
c.
Staf
f tra
inin
g
Co
nta
min
atio
n fr
om
pes
ts,
fore
ign
bo
die
s o
r ‘d
irty
’fo
od
ssu
ch a
s ro
ot
veg
etab
les
Dam
aged
/ru
sty
can
s
Gro
wth
of f
oo
d s
po
ilag
eb
acte
ria/
mo
uld
s,es
pec
ially
ifd
amp
/hu
mid
co
nd
itio
ns
Spo
ilag
e re
sult
ing
fro
mfa
ilure
to
ro
tate
sto
ck
Gre
enin
g/s
pro
uti
ng
of
po
tato
es (s
ola
nin
)
Sto
rag
e w
ith
/ad
jace
nt
toch
emic
als
Ch
eck
for
sig
ns
of p
ests
,d
amp
nes
s,d
amag
ed p
acka
gin
g,ru
sty
can
s,o
ut-
of-
dat
e st
ock
thro
ug
ho
ut
the
wee
k.Re
cord
ob
serv
atio
ns
(F)
Ch
eck
reco
rds
mo
nth
ly (S
)
Mo
nth
ly h
ygie
ne
aud
it (S
)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Co
mp
eten
cy t
esti
ng
(S)
PEm
plo
y re
pu
tab
le p
est
con
tro
l co
ntr
acto
r(M
)
Dis
card
infe
sted
or
con
tam
inat
ed fo
od
(S)
Bu
ildin
g m
ain
ten
ance
to
rem
ove
dam
pn
ess/
imp
rove
ven
tila
tio
n (M
)
Rein
stru
ct/r
etra
in (S
)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
FC
ON
TRO
L M
EASU
RES
CC
P
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
hyg
ien
e an
d g
oo
d p
erso
nal
hyg
ien
e,ef
fect
ive
clea
nin
g/d
isin
fect
ion
,pes
t m
anag
emen
t an
dw
aste
man
agem
ent.
*If t
her
e is
a d
evia
tio
n it
mu
st b
e in
vest
igat
ed t
o a
scer
tain
wh
y th
e d
evia
tio
n o
ccu
rred
.S=
Sup
ervi
sor
F=
Foo
d h
and
ler
M=
Man
ager
QC
=Q
ual
ity
con
tro
l
Staf
f tra
inin
g r
elat
es s
pec
ifica
lly t
o a
war
enes
s an
d d
etec
tio
n o
f haz
ard
s,th
eir
con
tro
l an
d m
on
ito
rin
g e
tc.
+Pr
ovi
ded
a c
ore
tem
per
atu
re o
f at
leas
t 75
°C is
ach
ieve
d d
uri
ng
co
oki
ng,
thaw
ing
is n
ot
a cr
itic
al c
on
tro
l po
int.
Ho
wev
er,i
f co
oki
ng
is b
ased
on
a t
ime
and
tem
per
atu
re t
hen
th
awin
g m
ay b
e a
crit
ical
co
ntr
ol p
oin
t.In
this
cas
e “c
om
ple
te t
haw
ing”
wo
uld
be
the
crit
ical
lim
it.
Prep
arat
ion
(th
awin
g o
f raw
foo
d)
Ensu
re t
haw
ing
of r
aw m
eat
is c
arri
ed o
ut
enti
rely
sep
arat
e fr
om
hig
h-r
isk
foo
d
Cle
an a
nd
dis
infe
ct s
urf
aces
aft
er t
haw
ing
Follo
w m
anu
fact
ure
r’s in
stru
ctio
ns
Use
ap
pro
pri
ate
syst
em t
o e
nsu
re t
he
foo
d,es
pec
ially
join
ts o
f mea
t an
d p
ou
ltry
,is
com
ple
tely
th
awed
,fo
r ex
amp
le,t
haw
ing
cab
inet
,co
ld r
oo
m (1
0°C
to
15°
C)
Allo
w s
uff
icie
nt
tim
e fo
r th
awin
g
Wh
en c
om
ple
tely
th
awed
pla
ce in
refr
iger
ato
r o
r co
ok
imm
edia
tely
Trai
nin
g o
f fo
od
han
dle
rs
Co
nta
min
atio
n o
f hig
h-r
isk
foo
d fr
om
th
awin
g r
aw fo
od,
esp
ecia
lly p
ou
ltry
Inad
equ
ate
tim
e fo
r th
awin
g,re
sult
ing
in u
nd
erco
oki
ng
and
su
rviv
al o
f bac
teri
a
Mu
ltip
licat
ion
of f
oo
dp
ois
on
ing
bac
teri
a b
ecau
seo
f th
awed
foo
d l
eft
atam
bie
nt
tem
per
atu
res
Au
dit
sys
tem
mo
nth
ly
(S)
Ch
eck
each
bat
ch o
f po
ult
ry is
thaw
ed -
leg
s an
d w
ing
s p
liab
le,
cavi
ty ic
e fr
ee (F
)
Use
a t
emp
erat
ure
pro
be
(F)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Co
mp
eten
cy t
esti
ng
of f
oo
dh
and
lers
(S)
N+
Des
tro
y an
y co
nta
min
ated
hig
h-r
isk
foo
d(S
)
Co
nti
nu
e th
awin
g u
nti
l co
mp
lete
(F)
Purc
has
e a
thaw
ing
cab
inet
(M)
Issu
e n
ew in
stru
ctio
ns
or
retr
ain
foo
dh
and
lers
(S)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
Co
oki
ng
(pro
cess
ing
)U
se a
cle
an s
po
on
for
tast
ing
Ensu
re fo
od
is c
oo
ked
for
the
app
rop
riat
eti
me
and
tem
per
atu
re.
Juic
es fr
om
join
ts o
fm
eat
sho
uld
ru
n c
lear
(Ta
rget
tem
p 7
8ºC
)
Pou
ltry
- co
ok
stu
ffin
g s
epar
atel
y
Ensu
re fr
ozen
join
ts/p
ou
ltry
are
co
mp
lete
lyth
awed
The
bas
e o
f pan
s sh
ou
ld n
ot
exce
ed t
he
hea
t so
urc
e
Sim
mer
ing
/bu
bb
ling
of s
tew
s an
d s
auce
saf
ter
stir
rin
g
Kee
p li
ds
on
Use
foo
d g
rad
e co
oki
ng
eq
uip
men
t e.
g.st
ain
less
ste
el
Staf
f tra
inin
g
Co
nta
min
atio
n in
tro
du
ced
e.g.
fro
m t
asti
ng
Mu
ltip
licat
ion
of f
oo
dp
ois
on
ing
bac
teri
a b
ecau
seo
f th
e p
rolo
ng
ed t
ime
ind
ang
er z
on
e
Surv
ival
of f
oo
d p
ois
on
ing
bac
teri
a d
ue
to in
adeq
uat
eco
oki
ng
/pro
cess
ing
Ch
emic
al c
on
tam
inat
ion
fro
mu
nsa
tisf
acto
ry e
qu
ipm
ent
Mo
nth
ly a
ud
it (S
)
Usi
ng
a d
isin
fect
ed p
rob
eth
erm
om
eter
- c
hec
k th
e ce
ntr
ete
mp
erat
ure
of e
ach
bat
ch h
asac
hie
ved
a t
arg
et o
f 78°
C a
nd
reco
rd (F
)
Vis
ual
ch
eck
each
bat
ch o
f fo
od
(F)
Ch
eck
coo
kin
g/p
roce
ssin
gre
cord
s w
eekl
y (S
)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
On
-go
ing
co
mp
eten
cy t
esti
ng
(S)
P Y7
5°C
Co
nti
nu
e co
oki
ng
un
til c
entr
e te
mp
erat
ure
of a
t le
ast
75°C
ach
ieve
d.Re
ject
un
safe
pro
du
ct w
hen
it is
no
t p
oss
ible
to
co
nti
nu
e(S
)
Mai
nte
nan
ce/r
epla
cem
ent
of e
qu
ipm
ent
(M)
Allo
w lo
ng
er t
ime
for
coo
kin
g in
th
e fu
ture
(QC
)
Car
ry o
ut
coo
kin
g t
rial
s to
ob
tain
mo
rein
form
atio
n (Q
C)
Rep
lace
co
oki
ng
eq
uip
men
t
Issu
e n
ew in
stru
ctio
ns
to fo
od
han
dle
rs (S
)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
Co
olin
gK
eep
foo
d c
ove
red
an
d c
om
ple
tely
sep
arat
efr
om
raw
foo
d
Port
ion
/slic
e jo
ints
wit
h a
dis
infe
cted
kn
ife
Co
ol f
oo
d r
apid
ly,(
60ºC
to
21º
C <
2 h
rs 2
1ºC
to 7
ºC <
4 h
rs) p
refe
rab
ly w
ith
a b
last
ch
iller
(<10
°C w
ith
in 2
ho
urs
)
Min
imis
e w
eig
ht
and
th
ickn
ess
of j
oin
ts
Dec
ant
sau
ces/
stew
s in
to s
hal
low
con
tain
ers
Use
iced
wat
er
Plac
e in
th
e ch
iller
as
soo
n a
s p
oss
ible
(sh
ou
ld n
ot
rais
e th
e te
mp
erat
ure
wit
hin
the
chill
er)
Co
ver
foo
d a
nd
use
a fa
n t
o p
rom
ote
air
mo
vem
ent
(rai
se fo
od
off
su
rfac
e)
Spra
y b
agg
ed fo
od
s w
ith
co
ld w
ater
Ric
e,ve
get
able
s,p
asta
& p
ota
toes
can
be
coo
led
wit
h r
un
nin
g c
old
wat
er
Refr
iger
ate
bel
ow
5°C
wh
en c
oo
l
Staf
f tra
inin
g
Co
nta
min
atio
n fr
om
foo
dp
ois
on
ing
bac
teri
a,fo
reig
nb
od
ies,
chem
ical
s o
r in
sect
s,es
pec
ially
flyi
ng
inse
cts
Mu
ltip
licat
ion
of f
oo
dp
ois
on
ing
bac
teri
a n
ot
des
troy
ed d
uri
ng
co
oki
ng
Ger
min
atio
n o
f sp
ore
s
Mo
nth
ly a
ud
its
(S)
Ch
eck
and
rec
ord
cen
tre
tem
per
atu
res
of e
ach
bat
chw
ith
a d
isin
fect
ed p
rob
eth
erm
om
eter
(F)
Ch
eck
tim
e/te
mp
erat
ure
rec
ord
sd
aily
(S)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Co
mp
eten
cy t
esti
ng
(S)
P Y
Ab
sen
ce o
fco
nta
min
atio
n
+60
°C to
21º
C >2
.5 h
rs
21ºC
to 7
ºC >
5 hr
s
Reje
ct u
nsa
tisf
acto
ry o
r co
nta
min
ated
pro
du
ct (S
)
Purc
has
e a
bla
st c
hill
er (M
)
Red
uce
siz
e o
r w
eig
ht
of p
rod
uct
(QC
)
Car
ry o
ut
coo
ling
tri
als
to o
bta
in m
ore
info
rmat
ion
(QC
)
Purc
has
e p
re-c
oo
ked
co
ld m
eat
(QC
)
Rein
stru
ct/r
etra
in (S
)
PR
OC
ESS
STEP
HA
ZA
RD
S A
ND
SOU
RC
ES
CA
USE
S O
F
CO
NTR
OL
MEA
SUR
ESC
CP
Y/N
/P
CR
ITIC
AL
LIM
IT
MO
NIT
OR
ING
(IN
CLU
DE
FREQ
UEN
CY
an
d
TAR
GET
S)
CO
RR
ECTI
VE
AC
TIO
N A
ND
RES
PO
NSI
BIL
ITY
(pro
du
ct a
nd
acti
on
to
bri
ng
th
e C
CP
un
der
con
tro
l)*
HA
CC
P C
on
tro
l Ch
art
Dat
e:...
......
......
......
.....
......
..Ap
pro
ved
by:
......
......
......
......
......
......
.....
......
Pag
e ...
......
......
....o
f ...
......
......
P =
pre
req
uis
ites
- ap
pro
ved
su
pp
liers
,pre
mis
es a
nd
eq
uip
men
t w
ell d
esig
ned
an
d m
ain
tain
ed,s
taff
tra
ined
in g
ener
al fo
od
saf
ety
and
go
od
per
son
al h
ygie
ne,
effe
ctiv
e cl
ean
ing
/dis
infe
ctio
n,p
est
man
agem
ent
and
was
te m
anag
emen
t.*I
f th
ere
is a
dev
iati
on
it m
ust
be
inve
stig
ated
to
asc
erta
in w
hy
the
dev
iati
on
occ
urr
ed.
S=Su
per
viso
r F
=Fo
od
han
dle
r M
=M
anag
er Q
C=
Qu
alit
y co
ntr
ol
St
aff t
rain
ing
rel
ates
sp
ecifi
cally
to
aw
aren
ess
and
det
ecti
on
of h
azar
ds,
thei
r co
ntr
ol a
nd
mo
nit
ori
ng
etc
.
Ch
illed
or
ho
td
isp
lay
Kee
p fo
od
co
vere
d/p
rote
cted
Prev
ent
cust
om
er c
onta
min
atio
n
Pro
vid
e sn
eeze
scr
een
s
Tota
l sep
arat
ion
of r
aw a
nd
hig
h-r
isk
foo
dse
rvic
e
Kee
p fo
od
bel
ow
5°C
or
abo
ve 6
3°C
Sell
wit
hin
sh
elf l
ife
Min
imis
e ti
me
that
bu
ffet
s ar
e at
am
bie
nt.
Des
tro
y le
ftov
ers
Equ
ipm
ent
mai
nte
nan
ce
Staf
f tra
inin
g
Co
nta
min
atio
n fr
om
equ
ipm
ent/
ute
nsi
ls o
r ra
wfo
od
Co
nta
min
atio
n fr
om
serv
ers/
wai
ters
Mu
ltip
licat
ion
of f
oo
dp
ois
on
ing
bac
teri
a/to
xin
pro
du
ctio
n b
ecau
se o
fp
rolo
ng
ed t
ime
at a
mb
ien
t
Mo
nth
ly h
ygie
ne
aud
its
(S)
Ch
eck
and
rec
ord
th
ete
mp
erat
ure
of r
efri
ger
ated
dis
pla
y ca
bin
ets
thro
ug
ho
ut
the
day
5°C
(F)
Ch
eck
and
rec
ord
th
ete
mp
erat
ure
of h
ot
dis
pla
ys a
sap
pro
pri
ate
:65°
C (F
)
Ch
eck
tem
per
atu
re r
eco
rds
(S)
Rep
ort
an
y p
rob
lem
s to
app
rop
riat
e su
per
viso
r (F
)
Co
mp
eten
cy t
esti
ng
P Y
Ab
sen
ce o
fco
nta
min
atio
n
8°C
fo
r 4
ho
urs
63
°C f
or
2 h
ou
rs
Reje
ct c
on
tam
inat
ed p
rod
uct
(F)
Des
tro
y co
nta
min
ated
pro
du
ct (S
)
Ad
just
tem
per
atu
re w
ith
th
erm
ost
at (F
)
Cal
l in
mai
nte
nan
ce e
ng
inee
r (S
)
Rep
lace
eq
uip
men
t/u
ten
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Corrective action
Deviation - failure to meet a critical limit
Corrective actionThe action to be taken when a critical limit is breached, i.e.a deviation occurs e.g. food temperature in fridgeexceeds 8°C for 4 hours. Remedial action, based ontarget levels, should be taken before a deviation occursi.e. before the critical limit is breached.
The action taken must bring the CCP under control anddeal with any affected product e.g. call in engineer -destroy high-risk food.Records of deviations and corrective action must bemaintained
In practice target levels are usually monitored so thata CCP can be brought back under control before thereis a need to destroy food. For example, targettemperature is set at 5ºC, on monitoring thetemperature it is found to be 6ºC so the thermostat isadjusted to reduce the temperature to 5ºC.
ExamplesChicken centre temperature after cooking 73°C.Critical limit is 75°C, target level is 78°C, therefore adeviation has occurred. Operator, places chicken backin oven until temperature of 78°C is achieved. Allactions are recorded.
Investigate - why was there a deviation?1. Inadequate thawing2. Error in time taken out of oven3. Size of bird larger than previously cooked4. Faulty oven
During the bean canning process the retort suffers aloss of steam pressure. The operator adds anadditional processing time as required by writtendeviation procedures.On completion of canning the batch of canned beansare quarantined pending QC assessment of writtenrecords and temperature charts. Bacteriologicalsampling may be undertaken before release.
Procedures for corrective actionsshould specify:
• What action is to be taken
• Who is responsible for the action - clear chain of command
• Who should be notified
• Whether production/sales should be stopped
• Treatment of affected product (including quarantine,testing, reprocessing and recall)
• Who can authorise production/sale to restart
After rectification of a deviation monitoring may needto be more frequent until control is assured
Product subject to deviation
Corrective action should specify the treatment of affected product (quarantine, testing, reprocessing, disposal andrecall)
Continue process (e.g. extend cooking time)
Change shelf life (e.g. use immediately)
Release after examination/sampling/testing
Use for different purpose
Release
Destroy
Traceability and recall (retail andmanufacture)
All products to be :• Clearly labelled
Clear identification of batches is alsoessential (retail and manufacture).Identification of batches containing specific ingredients
• TraceableTraceability of products is essential,including capability for recall.
Examples of major recallsJohn West Salmon - all cans from suspect batches withpossible C. botulinum.
John Barr (E. coli O157)- attempted to preventconsumption of contaminated cooked meat. (May havebeen frozen by consumers).
Recalls - use trade/enforcement officers/media - publicannouncements (TV, radio, newspapers)
May be seen as good hygiene practice and thereforebe considered as a prerequisite
NB Latest EU legislation re traceability.
MODULE 13
Verification Principle 6: Establish verification procedures toconfirm that the HACCP system is working effectively
Outcomes
The delegate will know and understand how to:
• define verification, validation, review and maintenance
• explain the need to verify the HACCP system
• explain what is involved with verification of the HACCP system
• explain the type of audits
• explain the need to validate elements of the HACCP plan to ensure they are effective
• explain the need to review the HACCP system,whenever significant changes occur or significant food safety problems/complaints occur
• explain the need to update and maintain the HACCP plan
VerificationStage 1 (validation)
Obtaining evidence that elements of the HACCP plan areeffective, especially the critical control points and criticallimits. This may require external expertise.
Stage 2Ensure that the HACCP system in total is satisfactory.(HACCP plan and prerequisites)
VerificationThe application of methods, procedures and tests, andother evaluations, in addition to monitoring, to determinecompliance with the HACCP plan.Verification techniques include inspection/auditing, bya technically competent person. Data and complaintanalysis (look for trends) microbiologicalmonitoring(end-product testing and/or production).Observe monitoring person.Check all documentation and records.
ExampleMonitoring of milk pasteurization - time/temp checkedon thermograph.Verification could involve bacteriological samplingand also validating the accuracy of the thermographsused to maintain temperatures of pasteurization
Stage 3 (Review)A reassessment of the HACCP system to ensure itscontinued validity.
Frequency of verificationShould occur at a frequency to ensure the HACCP planis being followed continuously i.e. safe food produced
All verification documentation should be recorded.
Verification techniques
May require external expertise
Audit against the HACCP plan to ensure correctimplementation and control of hazards. (involve foodhandlers) Inspection/audit skills required (preferableto use non-HACCP team member)
Use of random testing/sampling (includingmicrobiological
Challenge testing
Re-examine all scientific data relating to hazards andrisks
Focus on critical areas (e.g. what causes foodpoisoning)
Confirm that all CCPs are under control
Data and complaint analysis
Research/awareness of new technology, science anddevelopments especially in relation to epidemiologicalinformation
Audit (types)First party - internalSecond party - customersThird party - independent expertsFourth party - enforcement agencies
In the UK verification of small catering/retail businessmay have to be undertaken by enforcement officers.
When to review the HACCP system
A review should be undertaken:• At regular intervals (at least annually)• If new scientific data emerges (new
technology/epidemiological information)• When a justified complaint or confirmed illness occurs• When the raw materials or recipe changes• When equipment or the process is changed• Storage conditions or product use changes• Packaging or distribution is changed• Following modification of the HACCP plan
Review documentation must be recorded
NB Changes in the food operation or HACCP plan mayrequire additional training of food handlers to ensurecompetence
Annual reviews Useful to identify new products/processes or menuitems that have not been included in the HACCPsystem.
Similarly, changes to equipment or suppliers
Reviews should identify weaknesses in the system andeliminate unnecessary or ineffective controls
Maintenance of the HACCP system
Maintaining the supporting elements and resources toensure the plan remains valid over time and doesn’tbecome out of date.
Maintain• The HACCP team• The sources of information• The HACCP documentation
Module 14
Documentation Principle 7: Establish documentation concerning all procedures and records appropriate to theseprinciples and their application
Outcomes
The delegate will know and understand how to:
• explain the need for documentation of HACCP systems
• explain the need for keeping documentation upto date and removing obsolete instructions
• describe the type of documentation required to support the HACCP plan
• demonstrate the ability to prepare and complete monitoring records for CCPs and prerequisite programmes
• explain how to establish records for controlling procedures
• explain how to store completed records
Documentation
Accurate records are essential to the application of theHACCP system.
Must be appropriate for the size and nature of thebusiness.
Documentation is required for:• Company policy• Verification/internal audits• To investigate complaints/illness• Due diligence• Legal compliance• External auditors/EHOs
A management system to ensure up-to-date andeffective documentation is essential.
Utilize the simplest effective record-keeping systemthat integrates with the operation
Obsolete instructions/documentation must always bewithdrawn.
Documentation to support theHACCP study(Obtained during the operation of the plan)
• The HACCP plan • Floor plan• Prerequisite programmes• Audit reports of suppliers (where practicable)• Monitoring records of deliveries/specifications• CCP monitoring activities (and non CCPs)
(temperature/time/weight/chemical/bacteriological e.g. Rezasurin)
• Deviations and corrective actions• Inspection/audit reports• Customer complaints/investigation results• Prerequisite programmes’ monitoring activities• All monitoring records should be signed and dated
(countersigned if appropriate)
Records from prerequisite programmes include:• Approved supplier list• Stock rotation/date code• Staff health/exclusion/personal hygiene records• Cleaning schedules• Training programme/training records• Pest control (pest control book)• Equipment maintenance/servicing• Labelling• Calibration of instruments• Recall and traceability
Employees involved in monitoring can assist inensuring records and record-keeping procedures aresimple and effective
The HACCP plan:
• Details of the HACCP team and responsibilities
• Scope and terms of reference
• A description of the process, product and intended use
• Flow diagrams including CCPs
• Consumers
• All information relating to the hazard analysis and CCP determination (HACCP control charts)
• Critical limits and targets (evidence for justification)
• Deviations and corrective action procedures including reject, recall and traceablility
• Monitoring and record-keeping procedures
• A record of the reasons for critical decisions and modifications to the system
• Validation, verification and review procedures
Failure in the implementation ofHACCP
• Poor hygiene practices (prerequisites)• Lack of management commitment• Externally imposed• Lack of resources, especially time (for
implementation, monitoring, verification and review)
• Too complex (unnecessary jargon)not understood
• Lack of knowledge/training• Poor records/too much paperwork• System sits in manager’s office (HACCP should be
brought into food rooms and critical control points clearly identified)
• Too many critical control points identified• Not science based• Straying into quality not safety• Failure to reduce monitoring, emphasis on
controls that are not critical• Unreliable critical limits
3. What should be included within the scope of a HACCP study?
a) The labelling requirements of products.
b) The type and number of monitoring documents.
c) The number of people in the HACCP team.
d) The type of hazards that may affect the product.
2. One of the main principles of HACCP is to:
a) Define the terms of reference of a HACCP study.
b) Establish corrective actions.
c) Record the temperature of refrigerators 3 times per day.
d) Verify that the flow diagram is accurate.
a) Identifying steps in the activities which are critical to food safety.
b) Identifying members of a HACCP team.
c) Identifying critical control points using a decision tree.
d) Ensuring all high-risk food handlers have a HACCP qualification.
Section 1 Optional Questions
1. Which of the following is a legal requirement?
4.What is a decision tree used for?
a) To determine the pH of a product.
b) To identify hazards that may be present.
c) To identify critical control points within a process.
d) To identify critical limits.
5. Which of the following may be described as acontrol measure?
a) Checking the temperature of food with a probe thermometer.
b) Cooking a raw chicken to a safe temperature.
c) Recording accurate temperatures in a log book.
d) Analysing a process to ascertain likely hazards.
6. A review of the HACCP plan should be undertaken:
a) At least six times per year.
b) Following a food poisoning incident.
c) If a new laboratory has been selected.
d) When a new managing director is appointed.
7. Which of the following is an example of acorrective action?
a) Checking the temperature of food with a probe thermometer.
b) Verification of the flow diagram.
c) Calibrating the digital thermometer.
d) Detaining a suspect product for further testing.
8.Verification of the HACCP system should involve:
a) Obtaining evidence that the critical limits are being complied with.
b) Monitoring the refrigerator temperatures.
c) Ensuring that the ovens are regularly maintained.
d) Providing extensive training for the HACCP team members.
Try the following questions, answers follow
10. Which of the following is a routine monitoringprocedure in HACCP?
a) Identify the hazards in the raw ingredients.
b) Arranging for bacteriological testing of finished product.
c) Measuring the temperature of food in a refrigerator.
d) Assessing the knowledge of the high-risk food handlers.
a) Ensure the quality of the food is satisfactory
b) Determine the control measures required.
c) Provide training for HACCP team members.
d) Support a due diligence defence.
Section 1
9. Monitoring records kept to support the HACCPsystem are useful to?
11. What is the purpose of Industry Guides to Good Hygiene Practice?
12. The following graph shows the temperature of food in a refrigerator. After 45 minutes the door is left open.The maximum safe temperature is 8ºC. Place a letter in each box, from the list provided, to describe the specificline or point.
0ºC
5ºC
8ºC
0 15
C = Critical Limit D = Deviation H = Hazard M = Monitoring Point T = Target Temperature V = Verification Point
30 45 60 TIME (mins)
TEMP
13. The following graph shows the temperature of chickens removed from the oven after cooking. Thetemperature of the chicken removed after 3.5 hours is 73ºC. Place a letter in each box, from the list provided, todescribe the specific line or point.
0ºC
75ºC
78ºC
0 1
C = Critical Limit D = Deviation H = Hazard M = Monitoring Point T = Target Temperature V = Verification Point
2 3 4 TIME (HOURS)
TEMP
Section 1 ANSWERSIntermediate HACCP
Section 1:Question 1 Answer: aQuestion 2 Answer: bQuestion 3 Answer: dQuestion 4 Answer: cQuestion 5 Answer: bQuestion 6 Answer: bQuestion 7 Answer: dQuestion 8 Answer: aQuestion 9 Answer: dQuestion 10 Answer: c
Question 11 Answer: To provide a food business guidance on how to comply with legislation.
Question 12 Answer:
0ºC
5ºC
8ºC
0 15
C = Critical Limit D = Deviation H = Hazard M = Monitoring Point T = Target Temperature V = Verification Point
30 45 60 TIME (mins)
TEMP
Question 13 Answer:
T C D
0ºC
75ºC
78ºC
0 1
C = Critical Limit D = Deviation H = Hazard M = Monitoring Point T = Target Temperature V = Verification Point
2 3 4 TIME (HOURS)
TEMP T C D
Section 2 Q:1INTRODUCTION: You are assisting the HACCP team study food preparation in a small restaurant. Thescope of the HACCP study is microbiological contamination, multiplication and survival, including toxinsand spores, from delivery to service. You should assume the premises comply fully with legalrequirements.
PREPARATION: 20kg bags of dried rice are delivered weekly to a small restaurant. The bags arerejected if there is any indication of pest damage. After unloading the bags are emptied into clean bins inthe dry storage area. 5kg bags of frozen peas are delivered and stored at –18ºC. Deliveries above –15ºCare rejected. Black pepper is delivered as whole corns, moved to the dry store and ground as required.Tap water is added to the rice in large pans which is then boiled. Frozen peas are added to the rice whichis brought back to the boil. Some rice is plated and served immediately and some rice is held in a bainmarie above 63ºC until required for service. Ground black pepper is added to plated meals as required.Some rice is cooled using tap water at 10ºC, it is then placed under refrigeration below 5ºC. The followingday the rice is placed in a chilled display below 5ºC and served to customers as part of a salad.
Construct a process flow diagram from the information provided for the preparationand service of boiled rice,peas and black pepper.
Try this optional question, answer to follow
Q:1 AnswerINTRODUCTION: You are assisting the HACCP team study food preparation in a small restaurant. Thescope of the HACCP study is microbiological contamination, multiplication and survival, including toxinsand spores, from delivery to service. You should assume the premises comply fully with legalrequirements.
PREPARATION: 20kg bags of dried rice are delivered weekly to a small restaurant. The bags are rejectedif there is any indication of pest damage. After unloading the bags are emptied into clean bins in the drystorage area. 5kg bags of frozen peas are delivered and stored at –18ºC. Deliveries above –15ºC arerejected. Black pepper is delivered as whole corns, moved to the dry store and ground as required. Tapwater is added to the rice in large pans which is then boiled. Frozen peas are added to the rice which isbrought back to the boil. Some rice is plated and served immediately and some rice is held in a bain marieabove 63ºC until required for service. Ground black pepper is added to plated meals as required. Somerice is cooled using tap water at 10ºC, it is then placed under refrigeration below 5ºC. The following daythe rice is placed in a chilled display below 5ºC and served to customers as part of a salad.
Construct a process flow diagram from the information provided for the preparationand service of boiled rice,peas and black pepper.
DELIVERY –18ºC
STORE (FROZEN) –18ºC
Frozen Peas
TAPWATER
TAPWATER
DELIVERY
STORE (DRY)
GROUND
Black Pepper
DELIVERY
EMPTIED INTO BINS
STORE (DRY)
PLACED IN PANS
PLATED
SERVED HOT
SERVED COLD
Dry Rice
COOLED 10ºC
STORE (REFRIGERATOR) <5ºC
DISPLAY (CHILLED) <5ºC
BAIN MARIE 63ºC
BOILED 100ºC
Q:3Suggest one control measure for each of the following process steps.
Process Step
Refrigeratedstorage aftercooling
Chilled display
Multiplication of bacteria due tothe large amount of rice placedin the refrigerator
Multiplication of B. cereus due totemperature of chilled displaybeing at 20ºC
Control MeasureHazard & Source/Cause
Q:4Apply the Codex Decision Tree to the following process steps.There may be alternativecontrol measures but answers should only relate to the example provided.
Process Step
Cooking of rice
Hazard &Source/Cause
Survival ofvegetative B. cereus
Control Measures
Boil at100ºC
Decision Tree Questions(Put Yes or No as appropriate)
CCP?(Y/N)
1
Hot service ofrice immediatelyafter cooking
Multiplication of B. cereus
Serve within15 mins ofcooking
Chilled displayof cold rice
Multiplication of B. cereus
Store ricebelow 5ºC
1a 2 3 4
Q:2Bearing in mind the scope of the study identify a hazard and a source or cause of thehazard at each of the following steps.
Process Step
Cooking
Cooling
Hot Holding
Hazard & Source/Cause
Q:3 AnswerSuggest one control measure for each of the following process steps.
Process Step
Refrigeratedstorage aftercooling
Chilled display
Multiplication of bacteria due tothe large amount of rice placedin the refrigerator
Multiplication of B. cereus due totemperature of chilled displaybeing at 20ºC
Use small batches (less than 2.5cm). Cool rapidly <10ºC beforestoring in the refrigerator
Chilled display to operate at 5ºCor below
Control MeasureHazard & Source/Cause
Q:4 AnswerApply the Codex Decision Tree to the following process steps.There may be alternativecontrol measures but answers should only relate to the example provided.
*The answer to Q3 is 'NO' if 'could' is interpreted as 'is it likely' (using experience, science andepidemiological information). However, the answer to Q3 would be 'YES' if 'could' was interpreted as'is it theoretically possible'.
Process Step
Cooking of rice
Hazard &Source/Cause
Survival ofvegetative B. cereus
Control Measures
Boil at100ºC
Decision Tree Questions(Put Yes or No as appropriate)
CCP?(Y/N)
1
Y
Y
Y
Hot service ofrice immediatelyafter cooking
Multiplication of B. cereus
Serve within15 mins ofcooking
Chilled displayof cold rice
Multiplication of B. cereus
Store ricebelow 5ºC
1a
–
–
–
2
Y
N
N
3
–
N*
Y
4
–
–
N
Y
N
Y
Q:2 AnswerBearing in mind the scope of the study identify a hazard and a source or cause of thehazard at each of the following steps.
Process Step
Cooking
Cooling
Hot Holding
Survival of vegetative B. cereus due to inadequate cooking ( time andtemperature combination)
Long slow cooling enabling the germination of spores and themultiplication and toxin production of vegetative B. cereus
Multiplication and toxin production of vegetative B. cereus due totemperature dropping to around 40ºC
Hazard & Source/Cause
Q:6In a small factory involved with the production of jam several complaints were received fromcustomers regarding glass contamination.Earlier in the week engineers had dealt with aspate of broken glass jars during filling with jam and sealing of jars. They weren't surewhether the jars were suspect or the filling and capping line was faulty. However,they madesome adjustment to the line and no further problems occurred.
Do you agree with the actions taken?
Suggest an appropriate course of action including notes on the action that should have beentaken at the time of the breakage and how problems of this type could be prevented in thefuture.
Q:5 For each control measure that you have identified in Q:3 detail one suitable monitoringprocedure.
* WHAT/WHEN/WHO
Process Step
Refrigerated storageafter cooling
Chilled display
Monitoring*
At time of broken glass jars - Follow the glass policy regarding broken glassStop productionReject all empty or filled jars exposed to potential risk of contaminationInform competent authorityLook for any broken glassThoroughly clean up using separate cleaning equipment/brushes etc.Consider recall if suspect jars with broken glass have been sent out
Preventing future problems - Re-examine the glass policyTraining of staff/engineer regarding dealing with glass breakageSend glass jars for samplingCall in jar supplier/filler manufacturerIncrease checking/observation/maintenance of fillerMonitor trends in consumer complaintsConsider changing glass supplierCheck system for cleaning empty jars prior to fillingReview HACCP
Q:6 AnswerIn a small factory involved with the production of jam several complaints were received fromcustomers regarding glass contamination.Earlier in the week engineers had dealt with aspate of broken glass jars during filling with jam and sealing of jars. They weren't surewhether the jars were suspect or the filling and capping line was faulty. However,they madesome adjustment to the line and no further problems occurred.
Do you agree with the actions taken? I DO NOT AGREE WITH THE ACTION TAKEN
Suggest an appropriate course of action including notes on the action that should have beentaken at the time of the breakage and how problems of this type could be prevented in thefuture.
Q:5 AnswerFor each control measure that you have identified in Q:3 detail one suitable monitoringprocedure.
* WHAT/WHEN/WHO
Process Step
Refrigerated storageafter cooling
Chilled display
Food handler to check and record the temperature of eachbatch of rice with a clean,disinfected probe thermometerprior to refrigeration OR to check each batch to ensure thethickness does not exceed 2.5cm and daily checking oftemperature control records of refrigerator by supervisor.
Food handler to check and record the temperature of thechilled display at least 3 times per day and daily checking ofthe temperature control records by the supervisor.
Monitoring*
