7/14/2005 IFT05-fd-safe-principles 1
FOOD SAFETY PRINCIPLES IN DEVELOPING PRODUCTS
FOR THE FOODSERVICE MARKETSession 25: Enhancing product development success
by combining food science and culinary arts
PRESENTED AT IFT ANNUAL MEETING AND FOOD EXPO
NEW ORLEANS, LOUISIANA, JULY 18, 2005
O. Peter Snyder, Jr., Ph.D.Hospitality Institute of Technology and Management
670 Transfer Road, Suite 21ASt. Paul, Minnesota 55114 USA
TEL 651 646 7077 FAX 651 646 [email protected] http://www.hi-tm.com
7/14/2005 IFT05-fd-safe-principles 2
RETAIL PROCESS INNOVATIONThe retail chef innovates new processes and products.
However, today, the chef must adhere to FDA-dictated process controls whereby specified hazards associated with a process are not always identified; critical levels for safety are not identified; the Food Safety Objective is zero illnesses; and equipment selection is often limited to NSF.
The FDA says, if a retail food operation implements HACCP and does its own scientifically correct process development, it can do any federal process. Unfortunately, the HACCP literature gives no specific food science principles for productinnovation.
This symposium is intended to a provide a source of HACCP information that retail food operators can follow to develop new processes that meet specific Food Safety Objectives.
7/14/2005 IFT05-fd-safe-principles 3
USING AMC-HACCP, AN OPERATOR CAN DO ANY PROCESS VALIDATED AS SAFE BY THE OPERATOR.
• Minimally processed, cook-store (for 45+ days) foods such as sous vide / vacuum-packed, chilled foods with shelf lives determined by the operator vs. cook-serve.
• Processes modified to conserve cooking and refrigeration energy • Food holding 41ºF, 7 days; 45ºF, 4 days; 50ºF, 2.4 days; 55ºF, 1.7 days, etc.• Selling food prepared in a home if the home cook is trained. • Thawing on the counter at room temperature (USDA). • Simplified dish machine operation. • Simplified fruit and vegetable washing (modified dish machine). • Pasteurizing all food beginning at 130ºF.• Peking duck room-temperature skin drying, 12 hours.• Garlic-flavored oil for the table• Korean rice cakes, room-temperature display, 24 hours.• Cooling food in 15 hours to 40ºF.• Fingertip rinse procedure in 1 gallon of water.• Pumping roasts and turkey up to 20% (USDA).• Fermented foods: sausage, cheese, yogurt, sauerkraut, kimchee, beer, wine,
vinegar.
7/14/2005 IFT05-fd-safe-principles 4
THE RAW FOOD CONTAMINATION PROBLEM
1370
7/14/2005 IFT05-fd-safe-principles 5
NATIONAL ADVISORY COMMITTEE ON MICROBIOLOGICAL CRITERIA FOR FOODS (NACMCF) Logic sequence for the application of HACCP to wholesale processing
PREREQUISITE PROGRAMS: Form the HACCP team; identify the system, products, services, customers, and processes, GMPs, etc.
PROCESS HACCP1. Conduct the hazard analysis. Identify process steps with hazards and level of the
hazard.(1) Do a risk analysis and decide which hazards are unacceptable risks.(1)
2. Apply HACCP decision tree to each step with unacceptable risks. Determine which steps are critical control points.
3. Establish critical limits for preventive measures associated with each CCP.4. Establish CCP monitoring requirements. Establish procedures for using the results
of monitoring to adjust the process and maintain control.5. Establish corrective action to be taken when monitoring indicates that there is a
deviation from an established critical limit.6. Establish procedures for verification that the HACCP system is working correctly.7. Establish effective record keeping procedures that document the HACCP system.
1, 2, 3, etc.Y/N1.
HACCP records
Verification procedures /
person(s) responsible
Corrective actions(s) / person(s)
responsible
Monitoring procedures / frequency / person(s)
responsible
Critical limits
Chemical, physical, biological hazards
CCPProcess step
7/14/2005 IFT05-fd-safe-principles 6
THE KITCHEN HACCP TEAMDOES A NACMCF-STYLE HACCP PLAN WITH RISK MANAGEMENT
Not sig sigSTEP
Verification and
Improvement
Corrective Action (by
HACCP team)
Monitoring / Self-Check
Hazard Control
B,C,P Hazard Analysis / Risk Assessment
CCP Step Description
STEP
1. Specify ingredients and flow chart the process / recipe.2. At each step, ask:
a. Is there a B,C,P hazard that can be at a level to make people ill, and is this the correct step to control it? Is it cost effective to control?
b. If yes, what validated control do we use?c. How does the cook monitor to verify control?d. If we lose control, what corrective action rules do we apply?e. How do we verify that we have control?
7/14/2005 IFT05-fd-safe-principles 7
FOOD OPERATIONS RISK CONTROL MANAGEMENT
1904-ov&risk:food-op-haz-cont
• Risk = the likelihood of a hazard injuring a customer x the severity• Risk management is the responsibility of the owner / manager / chef (not regulatory
officials) to provide an Appropriate Level of Protection (ALOP) to their customers. Food liability insurance is for the residual low probability of an unanticipated event.
• Effective control of significant hazards is when a trained cook follows validated procedures to control hazards for an ALOP. The cook is then given positive reinforcement, and processes are evaluated periodically for improvement.
7/14/2005 IFT05-fd-safe-principles 8
THE OCCURRENCE OF AN ILLNESSREQUIRES MANY ERRORS.
Raw food is very contaminated, but very few meals cause illness.Why?
The customer must be
susceptible to the level
of the pathogen, and the
illness must be severe
The cook must not
correct the problem
OR management
must not observe and prevent the
problem
In the kitchen, the pathogen must be given time to multiply
(except Campylobacter
spp.) OR
the cook must cross-
contaminate OR
undercook
The fruit, vegetable, meat must
become contaminated
with a pathogen in
harvest / slaughter
The farmer must
have a colonized
animal
P5xP4xP3xP2xPT = P1
7/14/2005 IFT05-fd-safe-principles 9
POTENTIAL HAZARDS IN THE FOODCHEMICALPoisonous SubstancesToxic plant materialIntentional additivesChemicals created by the processAgricultural chemicalsAntibiotic and other drug residues Unintentional additivesSabotage / terrorismEquipment leachingPackaging leachingIndustrial pollutantsHeavy metalsRadioactive isotopesAdverse Food Reactions(food sensitivity)Food allergensFood intolerancesMetabolic disorderPharmacological reactionsIdiosyncratic reactionsAnaphylactoid reactions
BIOLOGICALMicroorganisms and their ToxinsBacteria: vegetative cells and sporesMolds (mycotoxins, e.g., aflatoxin)Yeasts (Candida albicans)Viruses and rickettsiaParasitesFish and shellfish as sources of toxic compoundsPests, animals (birds, insects and rodents) as carriers of pathogens Filth from insects, rodents, and any other unwanted animal parts or excreta
PHYSICALHard Foreign ObjectsGlassWoodStonesMetalPackaging materialsBonesBuilding materialsPersonal effectsFunctional HazardsParticle size deviationPackaging defectsSabotageChoking / Food Asphyxiation HazardsPieces of food Thermal HazardsFood so hot that it burns tissue
7/14/2005 IFT05-fd-safe-principles 10
PROCESS HACCP IS NOT JUST SEVEN PRINCIPLESHACCP has no process performance criteria / numbers. Applying HACCP principles, one uses food science to specify and develop process performance criteria and to set controls in a new process so as to achieve a desired consumer Appropriate Level of Protection (ALOP) / Food Safety Objective (FSO) (e.g., illness per 100,000 people; deaths per 1,000,000 people).
Biological, chemical, and physical contamination (baseline)Food from the farm
Distribution
Ingredient specifications (to reduce level of hazardsHazard and risk analysis to determine significant hazardsControl; to reduce significant hazards to an ALOPMonitoring to assure process stability and capability
Processor / kitchen
Food Safety Objective (FSO)
Consumer Appropriate level of protection (ALOP)
Process step example using process safety management language:Cook for a 5D reduction of Salmonella to get <1 Salmonella / 100 g
(Control measure) (Performance criterion) (Performance objective)
7/14/2005 IFT05-fd-safe-principles 11
HAZARD FOOD SAFETY OBJECTIVES
7/14/2005 IFT05-fd-safe-principles 12
THE RETAIL FOOD SAFETY MANAGEMENT SYSTEM
7/14/2005 IFT05-fd-safe-principles 13
MENU INGREDIENT HAZARD ANALYSISIngredients Supplier
Makes SafeIngredients Cook
Makes SafeBaked PotatoChicken parts and strips
CharlestonChicken NuggetsChicken Breast
Chicken Fried SteakCod, batteredShrimp, breadedBaconHamburger, Junior and RegularEggs (in-the-shell), over-easy, up,
hard-boiled, poachedSteak
T-boneSirloinCountry Fried Steak
Fresh Vegetables (e.g., Celery, Cilantro, Cucumbers, Onions, Peppers, Lettuce, Romaine, Mushrooms, Tomatoes, Parsley)
Fresh Fruits (e.g., Lemons, Limes, Grapes, Raw Fruit Mix)
CocoaTeasFruit Juices (e.g., orange,
apple, tomato, lemonade)
Soft Drinks (dispenser)Milk (Whole, 2%, skim,
chocolate)CreamAssorted Bread ProductsBagelsBiscuitsApple CrispFrozen Pies (Unbaked and
prepared)Frozen Cakes and
BrowniesOreo Cookie CrumblesIce CreamJams and JelliesSyrups (pancake) Syrups (for malts, sundaes
etc.)Caramel SauceVinegar,Sugar (brown, powdered)Crackers and CroutonsApple Topping
GritsOatmealVegetables, frozenColeslaw MixCanned Fruits (e.g.,
Cranberry and Apple Sauce)
Pico de GalloApplesauce SwimmersTaco ChipsSalsaCheeses (e.g., American,
Swiss, Cheddar, Parmesan, Cream Cheese, Cottage Cheese)
PicklesBBQ SauceCocktail SauceButterMargarineSpreads (Garlic, Sweet
Hickory)HoneySalad Dressings (e.g.,
coleslaw dressing, mayonnaise, tartar sauce, ranch dressing, etc.)
Condiments (e.g., ketchup, mustard)
CreamersCoffees
Mozzarella Cheese SticksPotatoes, parfried
French FriesSkilletHashed BrownsMashed
Onion Rings, parfriedOnion Tanglers, parfriedCorn Beef HashSausage Links, precookedHam Boca BurgerCheese PizzaTurkey Breast, fully cookedSmoked SausageSausage CrumblesNacho MeatRoast BeefEggs, liquid pasteurizedKraft Macaroni and CheeseFrench Toast Batter
(pasteurized ingred.)Pancakes (pasteurized
ingred.)Waffles (pasteurized ingred.)Gravies (pasteurized ingred.)SoupsMarinara SauceWing SauceStuffing
7/14/2005 IFT05-fd-safe-principles 14
PRODUCTS CAN BE GROUPED BY HACCP PROCESSHazards, Critical Controls, Limits (USDA HACCP, 9 CFR 417)
Shelf lifeHACCP Process
Commercially sterile, shelf stable. canned meat, fish, poultry; canned dairy products, canned vegetables
Fully cooked, with inhibitors to make shelf stable. marinara sauce; pie fillings; smoked fish; canned, low-pH fruits and vegetables; dry cereals, pasta
Fully cooked, not shelf stable. hot or cooled, refrigerated ready-to-eat food; meat, fish, poultry; fruits and vegetables, dairy
Not fully cooked, with inhibitors to make shelf stable. pepperoni; salami; ham; salted, dried fish; cheese; salad dressing; beer; wine
Not fully cooked, not shelf stable. Rare meat, fish, poultry; eggs, vegetables
Not heat treated, with inhibitors to make shelf stable. flour, nuts, salt, sugar, honey, spices and herbs, corn meal, oil and lard
Not heat treated, with secondary inhibitors, not shelf stable.corned beef
Not heat treated, not shelf stable. sashimi; lettuce and coleslaw salads; fruit salads; sprouts; yogurt; sauerkraut; kimchee; salsa
<14 daysI
<14 daysII
>2 years (chem. spoil)
III
<14 daysIV
>2 years (chem. spoil)
V
Hot <4 hoursCold 14-90 days
VI
>5 yearsVII
>5 yearsVII
7/14/2005 IFT05-fd-safe-principles 15
MENU ITEMS GROUPED BY HAZARD AND CONTROL CATEGORIES (Assumes that prerequisite programs are effective.)
7/14/2005 IFT05-fd-safe-principles 16
QUALITY-ASSURED HACCP RECIPE PROCEDURESPreparation time:Prepared by:Supervisor:
Portion size (vol./wt.):Number of portions:Final yield (AS):
Recipe name:Production style:Written by: Date:SA/QA by: Date:
Ingred. #
As Served (weight
Edible Portion (EP) (wt. or vol.)
EP Weight %
Ingredients and Specifications
Gp. #
Ingredients that could produce possible allergic reactions: Prerequisite ProceduresSSOPs / GMPs. Control chemicals. Remove physical hazards from food. Double wash fingertips / personal hygiene (6-log reduction). Sanitize food contact surfaces (5-log reduction). Train. QC. Buy food and store.
Pre-preparation1. Get food for recipe, <3-log increase Listeria monocytogenes (PHF <41ºF).2. Thaw <70ºF. 3. Do pre-prep. No time-temperature hazard. No CCP.
7/14/2005 IFT05-fd-safe-principles 17
QUALITY-ASSURED HACCP RECIPE PROCEDURES (cont'd)
Preparation4. CCP. If making salad with uncooked ingredients, double wash all
fruits and vegetables to reduce vegetative pathogens 2 log.5. CCP. Cook for 5-log Salmonella reduction (155ºF, 15 seconds).
Hold / Serve6. Hot hold, transport, serve. No growth of Clostridium perfringens
(>125ºF).
Leftovers7. CCP. Cool to prevent <1-log increase of Clostridium perfringens
(135 to 41ºF, <14 hours; <2 inches deep or 1-gallon pot).8. Cold hold, <3-log increase Bacillus cereus. If making cold mixed
salad, get all ingredients <50ºF before mixing (PHF <41ºF).9. Throw leftovers away or hold <7 days and reheat to 165ºF, 15
seconds (<3-log increase Bacillus cereus). 10. CCP. For allergen control, do not combine / mix leftovers.
Process step time, hr./min.
End food ctr. temp., ºF
Temp. on / around food
Cover Yes/No
Container size HxWxL
(in.)
Thickest food dimension
(in.)
Start food ctr. temp.,
ºF
Process step #
7/14/2005 IFT05-fd-safe-principles 18
FOOD PROCESS FLOW CHARTING
Industrial Engineering Symbols
= Store (a CCP if other than at end) (1x)S∇
= Inspect (optimize after each CCP) (2x)I�
= Delay/Stage (a CCP, minimize) (1x)DD
= Transport (minimize) (2x)T⇨= Operate (minimize) (12x)OΟ
(CCP = Critical Control Point) Food is made safe to eat
7/14/2005 IFT05-fd-safe-principles 19
FOOD PROCESS FLOW CHARTING (cont'd)
STEP DESCRIPTION CARD
7/14/2005 IFT05-fd-safe-principles 20
CHICKEN CACCIATORE RECIPE HACCP PROCEDURES AND RECORD
7/14/2005 IFT05-fd-safe-principles 21
CHICKEN CACCIATORE HACCP RECIPE FLOW
S=StoreD=DelayT=TransportI=InspectO=operate
7/14/2005 IFT05-fd-safe-principles 22
FOOD ADDITIVESFat SubstitutesSimplessePolydextroseOlestra
AntimicrobialsSaltSugarAcids
Nutritional additives
Texture-improvingGumsStarchesMicrocrystalline celluloseCarboxymethylcellulosePolydextroseAnticaking agentsDough conditionersEmulsifiersHumectantsMeat tenderizers
Nitrates and Nitrites
Sulfites
Irradiation
Indirect additivesProduction aidsAdjuvantsSanitizersPaper board componentsAdhesives and coatingsPolymers
Colors and flavor additivesSugarsHerbsSalt Monosodium glutamate
Color and flavor preservativesAntioxidants
Ascorbic acidBHA BHT Erythorbic acidPropionic acidSodium erythorbateTBHqTocopherols
Chelating agentsDisodium EDTAPolyphosphatesCitric acid
7/14/2005 IFT05-fd-safe-principles 23
INGREDIENTS THAT CAUSE ADVERSE FOOD REACTIONS
Acids AlcoholAntioxidants BenzoatesCaffeine ChiliFood colorings Aza dyesFructose GlutamatesCapsaicin Histamine Nitrates PepperPhenolic substancesSorbitol, natural sugars
Cow's milkLegumes
(includes peanuts)Crustacae, mollusksFishCornEggsWheatTree nuts
Food IntolerancesFood Allergens
The consumers must tell you that they are sensitive.
7/14/2005 IFT05-fd-safe-principles 24
SOME SOLUTES THAT ARE WATER ACTIVITY MODIFIERS
PEG 400LactuloseCitric AcidMaltoseAlanineSorbitolGlycerolNaClGlycine
PEG 600LysineOrnithineTartaric AcidProlineMalic AcidXyloseMannitolUrea
PolydextroseLactoseSucroseDE 42MaltoseGlucose / FructoseLactic AcidPropylene glycolKCl
7/14/2005 IFT05-fd-safe-principles 25
ANTIMICROBIAL ACTIVITY OF SPICES
Black pepper, red pepper, gingerWeak
Allspice, bay leaf, caraway, coriander, cumin, oregano,
rosemary, sage, thyme
Medium
Cinnamon, clove, mustardStrong
SpiceAntimicrobial Activity
Adapted from: Zaika, L.L. 1988. Spices and herbs: Their antimicrobial activity and its determination. J. Food Safety. 9:97-117.
7/14/2005 IFT05-fd-safe-principles 26
ORGANIC ACIDS AND ESTERS FOOD PRESERVATIVES
7/14/2005 IFT05-fd-safe-principles 27
PROCESS QUALIFICATIONA qualified process is one that the cook can demonstrate in operation that all necessary procedures, training, documentation, measurement, controls, and checks and balances are in place to ensure that the process can produce uniform-quality, safe food, even under stress conditions.• Until the performance of the process can be predicted, it is not in
control. To predict, the key process variables must be known, be controlled, and be repeatable.
• Correction – When you find a problem, remove the ROOT CAUSE of the problem.
• A "better" process means:
More stable: Cpk >1; More predictable; Safer =
Common and special causes known; Special causes being reducedWaste being reducedFaster productionBetter customer satisfaction
USL-X3σ
7/14/2005 IFT05-fd-safe-principles 28
PROCESS VALIDATIONPEER-REVIEWED RESEARCH REPORT
[Author(s)]IntroductionWhat is the process; what is the hazard; and what is the purpose of the report?MethodsHow were samples prepared?What microorganisms were used and source?What additives were used?How was the test conducted and controlled?How were the results measured?ResultsWhat were the data from the study, and how uniform were results?DiscussionDiscuss results in terms of the purpose of the studyConclusionsWas or was not the hazard effectively controlled?SummaryDate, Organization
7/14/2005 IFT05-fd-safe-principles 29
SUMMARY• Raw food will always be contaminated. The water and dirt farms
are not sterile. The cook must be able to look at food and decide what needs to be done to make it safe.
• Humans must eat pathogens at a safe level to maintain immune systems.
• Lawsuits for alleged illness will continue to increase. The cook / chef is the person who develops recipes and must be ready to validate and prove that he/she produced a safe food.
• Government retail food inspection does not certify that the foodserved is safe. Inspectors must empower managers and cooks to do self-control and "work themselves out of a job."
• Safe food starts with the menu. The chef must "HACCP" the recipes and train employees to do tasks with zero defects.
• The chef must innovate new process. HACCP is the procedure for self-certification.
• The chef must have a HACCP team and be improving processes and removing problems.