CHAPTER 7

WORKPLACE HYGIENE
LEARNING OUTCOMES
 Analyzing the importance of proper sanitation program in achieving correct level of hygiene in food
handling and production facilities.
 Listing the different steps included in the cleaning and sanitation programs.
 Describing the fundamentals of the overall cleaning procedure in the workplace.
 Classifying the different kinds of food particles or soils that are present in the equipment or
utensils in the kitchen.
 Identifying factors that influence the cleaning process.
 Differentiating the advantages and the disadvantages of selected chemical sanitizers.
 Enumerating the different types of waste produce in hospitality and food service operations and its
disposal system.

Cleaning and Sanitizing Program

A clean surface is defined as being free from soil (eg. food residues), free from bad A odors,
be non-greasy to the touch and have no visible oxidation (eg. rust). A sanitized clean surface is
defined as a clean surface that is substantially free from pathogenic microorganisms and undesirable
numbers of spoilage microorganisms. Cleaning prior to sanitizing is recommended as it increases the
effectiveness of the sanitizing step.

Effective cleaning and sanitation programs are required to achieve the correct level of hygiene
in food handling or production facilities. If these are not adhered to there is a greater risk of food
becoming contaminated by pathogenic or spoilage microorganisms. There is also a risk of biofilms
forming on factory and food preparation surfaces if these programs are inadequate. Biofilms are
complex aggregations of microorganisms and other materials which enhance survival and growth of
microorganisms; once formed they are very difficult to remove.

The lack of proper sanitation procedures can cost plant operators a lot of money. Often this
loss is not obvious to management. It shows up in terms of customers going elsewhere, poor
employee morale (this is sometimes blamed on inferior personnel), unreported spoilage problems or
poor food quality in restaurants (of equipment, overhead structures, shield walls, ceilings, lighting
devices, resulting in lack of repeat business). More obvious to management are direct complaints and
government intervention ranging from the local inspectors. Lack of proper sanitation can cause
increased returns of products, shorter shelf life, less profit and can invite the threat of possible
operation shutdown. Good Sanitation Does Not Cost, It pays.
Cleaning and sanitation programs include the following steps:
 Routine procedures performed throughout and at the completion of food processing or preparation
on a daily basis.
 Periodic procedures required less frequently.
 Monitoring to ensure the procedures are performed correctly.
 Verification to check effectiveness of the program.
 The safety of staff must be considered when developing these programs, including the safe
use of chemicals and hot water, and reducing manual labor.

Fundamentals Cleaning Procedure

The following is the typical procedure used when cleaning food processing equipment, The
factors that influence cleaning time, temperature, chemical concentration, and mechanical force), the
method of cleaning, and the food soils to be removed will ultimately determine the cleaning
procedures selected for use.

Scrape and Pre-Rinse: Soiled equipment surfaces are scraped and rinsed with warm water to
remove the gross amounts of loose food soils.
Cleaning Cycle: Removal of residual food soils from equipment surfaces through manipulation of the
four basic cleaning factors and the method of cleaning. Typically alkaline chemical solutions are used
for the cleaning cycle.
Rinse: Rinsing of all surfaces with cold to hot water, depending upon the temperature f the cleaning
cycle, to thoroughly remove all remaining chemical solution and food soil residues.
Acid Rinse: A mild acid rinse of the equipment neutralizes any alkaline residues left and removes
any mineral soil present.
Sanitize: All equipment surfaces are rinsed or flooded with a sanitizing agent. Time and
concentration are critical for optimum results.

REMOVAL OF FOOD PARTICLES

Scrape and flush large food particles from equipment and utensils before the items are placed
in a cleaning solution Spray the equipment and utensils with warm water. Avoid using very hot water
or steam because they tend to "bake" food particles on the surface of equipment and utensils and
that makes cleaning more difficult.
Properties of Food Soils
Food soil is generally defined as unwanted matter on food-contact surfaces. Soil is visible or
invisible. The primary source of soil is from the food product being handled. However, minerals from
water residue and residues from cleaning compounds contribute to films left on surfaces.
Microbiological biofilms also contribute to the soil buildup on surfaces.
Since soils vary widely in composition, no one detergent is capable of removing all types.
Many complex films contain: combinations of food components, surface oil or dust, insoluble cleaner
components, and insoluble hard-water salts. These films vary in their solubility properties depending
upon such factors as heat effect, age, dryness, time, etc.
It is essential that personnel involved have an understanding of the nature of the soil to be
removed before selecting a detergent or cleaning regime. The rule of thumb is that acid cleaners
dissolve alkaline soils (minerals) and alkaline cleaners dissolve acid soils and food wastes. Improper
use of detergents can actually "set" soils, making them more difficult to remove (e.g., acid cleaners
can precipitate protein). Many films and biofilms require more sophisticated cleaners which are
amended with oxidizing agents (such as chlorinated detergents) for removal.
 The physical condition of the soil deposits also affects its solubility. Freshly precipitated soil in
a cool or cold solution is usually more easily dissolved than an old, dried, or baked-on deposit, or a
complex film. Food soils are complex in that they contain mixtures of several components.

SOILS MAY BE CLASSIFIED AS:

Fat-based Soils
Fat usually is present as an emulsion and can generally be rinsed away with hot water above
the melting point. More difficult fat and oil residues can be removed with alkaline detergents which
have good emulsifying or saponifying ingredients.
Protein-based Soils
In the food industry, proteins are by far the most difficult soils to remove. In fact, casein (a
major milk protein) is used for its adhesive properties in many glues and paints. Food proteins range
from more simple proteins, which are casy to remove, to more complex proteins, which are very
difficult to remove. Heat-denatured proteins can be extremely difficult.
Generally, a highly alkaline detergent with peptizing or dissolving properties is required to
remove protein soils. Wetting agents can also be used to increase the wettability and suspendability
of proteins. Protein films require alkaline cleaners which have hypochlorite in addition to wetting
agents.
Carbohydrate-based Soils
Simple sugars are readily soluble in warm water and are quite easily removed. Starch
residues, individually, are also easily removed with mild detergents. Starches associated with proteins
or fats can usually be easily removed by highly alkaline detergents.
Mineral Salt-based Soils
Mineral salts can be either relatively easy to remove, or be highly troublesome deposits or
films. Calcium and magnesium are involved in some of the most difficult mineral films Under
conditions involving heat and alkaline pH, calcium and magnesium can combine with bicarbonates to
form highly insoluble complexes. Other difficult deposits contain iron or manganese. Salt films can
also cause corrosion of some surfaces. Difficult salt films require an acid cleaner for removal.
Microbiological Films
Under certain conditions, microorganisms (bacteria, yeasts, and molds) can form invisible films
(biofilms) on surfaces. Biofilms can be difficult to remove and usually require cleaners as well as
sanitizers with strong oxidizing properties.
Lubricating Greases and Oils
These deposits (insoluble in water, alkali, or acid) can often be melted with hot water or steam,
but often leave a residue. Surfactants can be used to emulsify the residue to make it suspendable in
water and flushable.
Other Insoluble Soils
Inert soils such as sand, clay, or fine metal can be removed by surfactant-based detergents.
Charred or carbonized material may require organic solvents.
Quantity of Soil
It is important to rinse food-contact surfaces prior to cleaning to remove most of the soluble
soil. Heavy deposits require more detergent to remove. Improper cleaning can actually contribute to
build-up of soil.
APPLICATION OF CLEANING AGENTS
A cleaning agent is a chemical compound formulated to remove soil and dirt. There are
methods of applying cleaning agents and solutions to the surfaces of equipment. Cleaning agents
typically include an acid or alkaline detergent and may include degreasers, abrasive materials, or a
sanitizer. Effectiveness and the economy of the method generally dictate its use.
Factors Influencing Cleaning
There are four interrelated factors which affect the overall cleaning process. When designing
cleaning procedures these factors need to be carefully considered.
 Soil: Depending upon the food product being manufactured and the process equipment used,
varying degrees of food soil will be deposited on the equipment during production. These food
soils will require complete removal during the cleaning process and will affect the cleaning
compound used, along with the method of cleaning
 Time: The longer a cleaning solution remains in contact with the equipment surface, the greater
the amount of food soil that is removed. Increasing time reduces the chemical concentration
requirements.
 Temperature: Soils are affected to varying degrees by temperature. In the presence of a cleaning
solution most soils become more readily soluble as the temperature is increased.
 Chemical Concentrations: Chemical concentrations vary depending upon the chemical itself, type
of food soil, and the equipment to be cleaned. Concentration will normally be reduced as time and
temperature are increased.
 Mechanical Force: Mechanical force can be simple hand scrubbing with a brush or as complex as
turbulent flow and pressure inside a pipeline. Mechanical force aids in soil removal and typically
reduces time, temperature, and concentration requirements.

Each of these factors for effective cleaning and can be modified to meet the needs of a
particular type of problem or set of conditions.

Methods of Cleaning Foam:

 Foam is produced through the introduction of air into a detergent solution as it is sprayed onto the
surface to be cleaned. Foam cleaning will increase the contact time of the chemical solutions,
allowing for improved cleaning with less mechanical force and temperature.
 High Pressure: High pressure cleaning is used to increase the mechanical force, aiding in soil
removal. In high pressure cleaning chemical detergents are often used along with increased
temperature to make soil removal more effective.
 Clean in Place (CIP): CIP cleaning is utilized to clean interior surfaces of tanks and pipelines of
liquid process equipment. A chemical solution is circulated through a circuit of tanks and or lines
then returned to a central reservoir allowing for reuse of the chemical solution. Time, temperature,
and mechanical force are manipulated to achieve maximum cleaning.
 Clean Out Of Place (COP): COP cleaning is utilized to clean tear down parts of fillers and parts
of other equipment which require disassembly for proper cleaning. Parts removed for cleaning are
placed in a circulation tank and cleaned using a heated chemical solution and agitation.
 Mechanical: Mechanical cleaning normally involves the use of a brush cither by hand or a
machine such as a floor scrubber. Mechanical cleaning uses friction for food soil removal.

Cleaning Compound Composition

There are two classes of cleaning compounds, alkaline and acid. Chemical formulations for
alkaline and acid compounds vary widely providing for selection flexibility when considering sanitation
procedures, types of processing equipment to be cleaned, chemical dispensing, and method of
cleaning.
Alkaline Compounds
 Sodium or Potassium Hydroxide: Hydroxides provide the largest portion of alkalinity and
effectively saponify fats and peptize proteins for removal
 Sodium Metasilicate: Aids in emulsifying and soil suspension along with protecting against metal
corrosion.
 Complex Phosphates: Phosphates primary function is to soften the water by chelating (binding up)
the calcium and magnesium hardness. This allows for better cleaning effectiveness and reduces
mineral deposits. Phosphates will also aid in emulsifying food soils.
 Surface Active Agents (Surfactants): Surfactants help break down the surface tension of soils to
improve removal. Once the food soil is removed the surfactant forms a colloidal suspension with
the soil, keeping it water soluble to prevent it from redepositing on the equipment surfaces.
 Chlorine: Chlorine is added to many chemical formulations to help in peptizing proteins.

Acid Cleaners

 Phosphoric Acid: Phosphoric acid provides the bulk of the acidity in most acid cleaners.
Phosphoric solubilizes minerals well and is less corrosive to metals than most other acids.
 Other Acidulants: Acetic, hydroxyacetic, citric, sulfamic, and nitric acids are also used in many
cleaners to a varying degree. Nitric acid use has expanded greatly due mainly to cost, however
nitric is very effective in the removal of tough mineral deposits in heat exchangers and
evaporators.
 Surface Active Agents (Surfactants): Surfactants help break down the surface tension of soils to
improve removal. Once the food soil is removed the surfactant forms a colloidal suspension with
the soil, keeping it water soluble to prevent it from redepositing on the equipment surfaces.

Chemistry of Detergents
Detergents and cleaning compounds are usually composed of mixtures of ingredients that
interact with soils in several ways:
 Physically active ingredients alter physical characteristics such as solubility or colloidal stability
 Chemically active ingredients modify soil components to make them more soluble and, thus,
easier to remove.
 In some detergents, specific enzymes are added to catalytically react with, and degrade, specific
food soil components.
Physically Active Ingredients

The primary physically active ingredients are the surface active compounds termed
surfactants. These organic molecules have general structural characteristic where a portion of the
structure is hydrophilic (water- loving) and a portion is hydrophobic (not reactive with water). Such
molecules function in detergents by promoting the physical cleaning actions through: emulsification,
penetration, spreading, foaming, and wetting.
The classes of surfactants are:
 lonic surfactants which are negatively charged in water solution are termed anionic surfactants.
Conversely, positively charged ionic surfactants are termed cationic surfactants. If the charge of
the water soluble portion is depended upon the pH of the solution it is termed an amphoteric
surfactant. These surfactants behave as cationic surfactants under acid conditions, and as anionic
surfactants under alkaline conditions. Ionic surfactants are generally characterized by their high
foaming ability.
 Nonionic surfactants, which do not dissociate when dissolved in water, have the broadest range of
properties depending upon the ratio of hydrophilic/ hydrophobic balance. This balance is also
affected by temperature.

It is a common practice to blend surfactant ingredients to optimize their properties. However,

because of precipitation problems, cationic and anionic surfactants cannot be blended

The Surface Characteristics

The cleanability of the surface is a primary consideration in evaluating cleaning effectiveness.
Included in surface characteristics are:
 Surface Composition. Stainless steel is the preferred surface for food equipment and is specified
in many industry and regulatory design and construction standards. For highly acidic, high salt, or
other highly corrosive products, more corrosion resistant materials (i.e. titanium) is often
recommended.
 Other "soft" metals (aluminum, brass, copper, or mild steel), or nonmetallic surfaces (plastics, or
rubber) are also used on food contact surfaces. Surfaces of soft metals and nonmetallic materials
are generally less corrosion-resistant and care should be exercised in their cleaning.
 Aluminum is readily attacked by acids as well as highly alkaline cleaners which can render the
surface non-cleanable. Plastics are subject to stress cracking and clouding from prolonged
exposure to corrosive food materials or cleaning agents.
 Hard wood (maple or equivalent) or sealed wood surfaces should only be used in limited
applications such as cutting boards or cutting tables provided the surface is maintained in good
repair. Avoid using porous wood surfaces.
 Surface Condition. Misuse or mishandling can result in pitted, cracked, corroded, or roughened
surfaces. Such surfaces are more difficult to clean or sanitize, and may no longer be cleanable.
Thus, care should be exercised in using corrosive chemicals or corrosive food products.
 Detergents can be significant contributors to the waste discharge(effluent). Of primary concern is
pH. Many publicly owned treatment works limit effluent pH to the range of 5 to 8.5. So, it is
recommended that in applications where highly alkaline cleaners are used, that the effluent be
mixed with rinse water (or some other method be used) to reduce the pH.
RINSING
Immediately after cleaning, thoroughly rinse all equipment surfaces with hot potable water to
remove the cleaning solution. This very important rinse step is necessary because the product or
detergent used for washing can interfere with the germ-killing power or sanitizer.

Water Quality
Water is the primary component of cleaning materials used in food establishments. The water
supply serving food establishments must be safe to drink (potable). Most establishments get their
water from a public supply. Establishments that have a private well should have it inspected at least
once a year and water samples tested at least once a year ensure the bacteriological safety of the
supply. Water must be free from harmful microorganisms, chemicals and other substances that can
cause diseases. While the water supply must be safe to drink, it may contain substances that affect
hardness, taste, and odors. Therefore, adjust cleaning agents to fit the characteristics of your water
supply and type of operation Water comprises approximately 95-99% of cleaning and sanitizing
solutions. Water functions to:
 carry the detergent or the sanitizer to the surface
 carry soils or contamination from the surface.

The impurities in water can drastically alter the effectiveness of a detergent or a sanitizer.
Water hardness is the most important chemical property with a direct effect on cleaning and sanitizing
efficiency. (Other impurities can effect the food contact surface or may effect the soil deposit
properties or film formation.)

Water pH ranges generally from pH 5 to 8.5. This range is of no serious consequence to most
detergents and sanitizers. However, highly alkaline or highly acidic water may require additional
buffering agents. Water can also contain significant numbers of microorganisms. Water used for
cleaning and sanitizing must be potable and pathogen-free. Treatments and sanitization of water may
be required prior to use in cleaning regimes.

SANITIZING PRINCIPLES

Heat and chemicals are the two types of sanitizers most commonly used in food
establishments. Sanitizers destroy disease-causing organisms which may be present on equipment
and utensils even after cleaning. Sanitization is not sterilization, because sonic bacterial spores and a
few highly resistant vegetative cells generally survive. In all instances, a food-contact surface must be
cleaned and then thoroughly rinsed to remove loosened soil and detergent residues that tend to
inhibit the sanitizer's action.

General types of sanitization include:

1. Thermal Sanitizing
Thermal Sanitization involves the use of hot water or steam for a specified temperature and
contact time as with any heat treatment the effectiveness of thermal sanitizing is dependant upon a
number of factors including initial contamination load humidity, pl. temperature, and time.
 Steam
 The use of steam as a sanitizing process has limited application. It is generally expensive
compared to alternatives, and it is difficult to regulate and monitor contact temperature and time.
Further, the byproducts of steam condensation can complicate cleaning operations.
 Hot Water

Hot water sanitizing--through immersion (small parts, knives, etc.), spray (dishwashers), or
circulating systems--is commonly used. The time required is determined by the temperature of the
water.

The primary advantages of hot water sanitization are: relatively inexpensive, easy to apply and
readily available, generally effective over a broad range of microorganisms, relatively non-corrosive,
and penetrates into cracks and crevices. Hot water sanitization is a slow process which requires
come-up and cool-down time, can have high energy costs, and has certain safety concerns for
employees. The process also has the disadvantages of forming or contributing to film formations, and
shortening the life of certain equipment or parts thereof (gaskets, etc.).

2. Chemical Sanitizing
Chemical Sanitization involves the use of an approved chemical sanitizer at a specified
concentration and contact time.

The ideal chemical sanitizer should:

 be approved for food contact surface application
 have a wide range or scope of activity.
 destroy microorganisms rapidly.
 be stable under all types of conditions.
 be tolerant of a broad range of environmental conditions.
 be readily solubilized and possess some detergency.
 be low in toxicity and corrosivity.
 be inexpensive.

Specific Types of Chemical Sanitizers

Chlorine-based Sanitizers
Chlorine Compounds. Chlorine, in its various forms, is the most commonly used sanitizer in
food processing and handling applications. Commonly used chlorine compounds include: liquid
chlorine, hypochlorites, inorganic chloramines, and organic chloramines. Chlorine-based sanitizers
form hypochlorous acid (HOCI, the most active form) in solution. Available chlorine (the amount of
HOCI present) is a function of pH. At pH 5, nearly all is in the form of HOCI. At pH 7.0, approximately
75% is HOCI. The maximum allowable level for no-rinse applications is 200ppm available chlorine,
but recommended usage levels vary.
Chlorine compounds are broad spectrum germicides which act on microbial membranes,
inhibit cellular enzymes involved in glucose metabolism, have a lethal effect on DNA, and oxidize
cellular protein Chlorine has activity at low temperature, is relatively cheap, and Ieaves minimal
residue or film on surfaces.
The major disadvantage to chlorine compound is corrosiveness to many metal surfaces
(especially at higher temperatures). Health and safety concerns can occur due to skin irritation and
mucous membrane damage in confined areas. At low pH (below 4.0), deadly Cl 2 (mustard gas) can
form.
Use of iodine as an antimicrobial agents dates back to the 1800s. This sanitizer exists in many forms
and usually exists with a surfactant as a carrier. These mixtures are termed iodophors. The most
active agent is the dissociated free iodine (also less stable). This form is most prevalent at low pH.
Iodine solubility is very limited in water. Generally recommended usage for iodophors is 12.5 to
25ppm for 1 min. It is generally thought that the bactericidal activity of iodine is through direct
halogenation of proteins. More recent theories have centered upon cell wall damage and destruction
of microbial enzyme activity.
Iodophors, like chlorine compounds, have a very broad spectrum, being active against bacteria,
viruses, yeasts, molds, fungi, and protozoans. Iodine is highly temperature-dependent and vaporizes
at 120°F. Thus, it is limited to lower temperature applications. Iodophors are generally less affected
by organic matter and water hardness than chlorine. However, loss of activity is pronounced at high
pH. disadvantage is that iodine can cause staining on some surfaces (especially plastics).

Quaternary Ammonium Compounds (QACs). QACs are active and stable over a broad
temperature range. Because they are surfactants, they possess some detergency. Thus, they are
less affected by light soil than are other sanitizers. However, heavy soil dramatically decreases
activity. QACs generally have higher activity at alkaline pH. While lack of tolerance to hard water is
often listed as a major disadvantage of QACs when compared to chlorine, some QACs are fairly
tolerant of hard water. QACs are effective against bacteria, yeasts, mold, and viruses.
QACs are generally more active against gram positive than gram negative bacteria. They are
not highly effective against bacteriophages. Their incompatibility with certain detergents makes
thorough rinsing following cleaning operations imperative. An advantage of QACs in some
applications is that they leave a residual antimicrobial film. However, this would be a disadvantage in
operations such as cultured dairy products, cheese, beer, etc. where microbial starter cultures are
used.
Table 7.1 Advantages and Disadvantages of Selected Chemical Sanitizers
SANITIZERS ADVANTAGES
Chlorine Compounds Economical cost Kills many Corrosive to
types of microbes Good for equipment Can imitate
most sanitizing applications human skin and hands
Iodophors Less corrosive to equipment Moderate cost Can
Less imitating to skin Good stain equipment
for killing germs on hands
Quaremary Stable at high temperature Very expensive
Stable for a longer contact
time Good in place sanitizers

Thermal Sanitizing vs. Chemical Sanitizing

Heat sanitizing has several advantages over chemical sanitizing agents because it:
 Can penetrate small cracks and crevices
 Is non-corrosive to metal surfaces
 is non-selective to microbial groups
 Leaves no residue
 Is easily measurable

Heat destroys vegetative bacteria cells by disrupting some of the protein molecules in the cells.
Moist heat is much more efficient in killing microorganism than dry heat. Heat sanitization is used in
both manual and mechanical ware washing operations.

FACTORS AFFECTING SANITIZER EFFECTIVENESS

Physical Factors
 Surface Characteristics. Prior to the sanitization process, all surfaces must be clean and
thoroughly rinsed to remove any detergent residue. An unclean surface cannot be sanitized. Since
the effectiveness of sanitization requires direct contact with the microorganisms, the surface
should be free of cracks, pits, or crevices which can harbor microorganisms. Surfaces which
contain biofilms cannot be effectively sanitized.
 Exposure Time. Generally, the longer time a sanitizer chemical is in contact with the equipment
surface, the more effective the sanitization effect. Intimate contact is as important as prolonged
contact.
 Temperature. Temperature is also positively related to microbial kill by a chemical sanitizer. Avoid
high temperatures (above 55°C [131°F]) because of the corrosive nature of most chemical
sanitizers.
 Concentration. Generally, the activity of a sanitizer increases with increased concentration.
However, a leveling off occurs at high concentrations. A common misconception regarding
chemicals is that "if a little is good, more is better". Using sanitizer concentrations above
recommendations does not sanitizer better and, in fact, can be corrosive to equipment and in the
long run lead to less cleanability. Follow manufacturer's label instructions.
 Soil. The presence of organic matter dramatically reduces the activity of sanitizers and may, in
fact, totally inactivate them. The adage is "you cannot sanitize an unclean surface"
 pH. Sanitizers are dramatically affected by the pH of the solution. Many chlorine sanitizers, for
example, are almost ineffective at pH values above 7.5. Water properties. Certain sanitizers are
markedly affected by impurities in the water. Inactivators. Organic and/or inorganic inactivators
may react chemically with sanitizers giving rise to non-germicidal products. Some of these
inactivators are present in detergent residue. Thus, it is important that surfaces be rinsed prior to
sanitization.

Biological Factors
The microbiological load can affect sanitizer activity. Also, the type of microorganism present is
important. Spores are more resistant than vegetative cells. Certain sanitizers are more active against
gram positive than gram negative microorganisms, and vice versa. Sanitizers also vary in their
effectiveness against yeasts, molds, fungi, and viruses.
Ware washing
Ware washing is the process of washing and sanitizing dishes, glassware, flatware, and pots
and pans either manually or mechanically. Manual ware washing uses three-compartment sink and is
used primarily for pots and pans. It may be used for dishes and flatware in small operations.
Mechanical ware washing requires a machine capable of washing, rinsing, and air drying dishes,
flatware, and glassware large operations, heavy-duty pot and pan washing machines have been
designed to remove cooked-on food.
MANUAL AND MECHANICAL WARE WASHING
Manual Dishwashing
Procedure
 Scrape and prerinse. The purpose of this step is to keep the wash water cleaner longer.
 Wash. Use warm water at 43-49 C and a good detergent. Scrub well with a brush to remove all
traces of leftover and grease.
 Rinse. Use clean warm water to rinse off detergent Change the water frequently or use running
water with an overflow.
 Sanitize. Place utensils in rack and immerse in hot water at 77C for thirty seconds. (a gas or
electric heating element is needed to hold hot water at this temperature).
 Drain and air-dry. Do not towel-dry. This may recontaminate utensils.

Mechanical Dishwashing
The steps in washing dishes by machine are the same as in the manual method. Except that
the machine does the washing, rinsing, and sanitizing. Procedure:
 Scrape and prerinse.
 Rack dishes so that the dishwater spray will strike all surfaces.
 Run machine for a full cycle.
 Set the sanitizing temperatures at 82 C for machine that sanitizes by heat and at 60 C for the
machine that sanitizes by chemical disinfectant.
 Air-dry and inspect dishes. Do not touch food-contact surfaces.

Table 7.2 Dishwashing Machines

TYPE OF MACHINE WASH TEMPERATURE RINSE TEMPERATURE
Single tank stationary rack 74°C 74°C
single temperature
machine
single tank, conveyor, dual 71°C 82°C
temperature
single tank stationary 66'C 82°C
temperature machine
chemical sanitizing 49°C 49°C
machine

PEST CONTROL
The importance of rodent and insect control cannot be emphasized enough. Rats, mice flies,
roaches, grain insects, fruit flies, and gnats all facilitate the transmission of communicable disease.
Therefore, it is essential for any foodservice to try to effect complete elimination of resident pest
infestations and then to correct conditions within establishment so that such pest cannot gain
entrance in the future.
All food establishments must have a pest control program. The benefits of proper cleaning and
sanitizing of equipment and utensils, time and temperature controls, and food handling can all be
wasted if insect and rodent are allowed to contaminate food and food-contact surface. Any food
establishment may have an occasional insect or rodent problem. However, their continual presence
cause major problem and indicate a lack of good sanitation and control measure.
The key element of a successful pest control program is prevention. However, no single
measure will effectively prevent or control insect and rodent in food establishments. It takes a
combination of three separate activities to keep pests in check. You Must:
 Prevent entry of insects and rodent into the establishment
 Eliminate food, water, and places where insect and rodent can hide.
 Implement an integrated pest management program to control insect and rodent pest that enter
the establishment.

PESTS IN FOOD SERVICE FACILITY

The house mouse is considered to be the most widespread terrestrial mammal in the world.
They are well adapted to living in close contact with humans and thrive in the conditions which man
provides, particularly where hygiene and house keeping standards are low. Mice can cause extensive
damage to property as a result of their gnawing activities, and also by eating and contaminating
human food. There is a significant risk of fire and electrocution as a result of mice chewing through
electric cables and wiring.

Mice carry a wide range of diseases, including Weil's Disease, which can be passed to
humans, either by directly contaminating food with droppings and urine or by contaminating surfaces.

Look Out For:

 droppings - these are normally about cm long and rod shaped;
 gnawing, particularly on sacks and boxes which may cause spillage of food.

Common Rats
Rats can carry a range of serious diseases transmittable to people, such as Weil's disease,
salmonella food poisoning and toxoplasmosis. They can infest and ruin foodstuffs and cause serious
structural damage to buildings, pipework and wiring systems - even causing fires - by their constant
gnawing.
Look Out For:
 droppings - these are normally about 3-5mm long and rod shaped:
 footprints and tail marks which may be seen in dust or on food;
 smears left by greasy, dirty fur rubbing against walls;
 holes through walls or floors or burrows in outside areas. These would need to be repaired
immediately.

Cockroach
They are usually found in areas of high temperature such as kitchens and offices. Many pathogenic
bacteria have been found to be carried by the common cockroach, including salmonella, gastro-
enteritis, and the tapeworm. Cockroaches are a major public health pest, responsible for economic
loss in food production from tainted stock, and the contamination of equipment and medical supplies.

Look Out For:

 Droppings
 Eggs

Ants

Worker ants are a nuisance as they forage widely for food and water following scent marked
trails. Although omnivorous they tend to prefer roteinaceous foods. They will feed on meat, cheese,
fats, sugar, honey, jam, chocolate etc. Ants pose a risk to health, Pathogenic organisms may be
transmitted mechanically as the ants feed in unhygienic places including drains, refuse bins, wound
dressings etc. The multi nesting behavior of this species means that if one area of a building is
infested, there is likelihood of extensive spread throughout the premises.

Moths

Moths can be found in a variety of stored products. Some species are associated with goods of
vegetable origin, to which they may be adapted with varying degrees of specificity, whilst others are
associated with animal products - particularly textiles. Moth larvae can cause considerable damage to
stored goods by feeding or by contaminating with their own products, eg, webbing and frass.

Common House Fly

Common house flies are ubiquitous insects, with a flight range of at least 8 kilometers (5
miles). They are highly active indoors. House Flies can transmit intestinal worms, or their eggs, and
are potential vectors of diseases such as dysentery, gastroenteritis, typhoid, cholera and tuberculosis.
They will frequently and indiscriminately feed on any liquefiable solid food, which may equally be
moist, putrefying material or food stored for human consumption.

Environmental Sanitation

The food service and hospitality industries have long been conscious of the importance of
environmental sanitation. The limited environments that restaurants and hotel provide must be clean
in order to appeal to customers. It is fundamental that any form of visible water should be removed
from the client's view and that the air in a restaurant or guest room should smell sweet and that the
water should taste pure.

The customer aids to operator in enforcing genuine sanitation by insisting sanitation Garbage
cannot accumulate to the point where it is impossible to hide nor can it be left to age to the point of
contaminating the atmosphere. Most operators do not have to be convinced of the importance of
removing solid waste, liquid waste, and bad air from their left to age to the point of contaminating the
atmosphere. Most operators do not have to be operations. They are concerned with the most
effective, efficient, and economical methods of accomplishing these tasks.

TYPES OF WASTE HOSPITALITY AND FOOD SERVICE OPERATIONS

 Waste volume and waste problems in hospitality and food service operations are constantly
increasing. Food service and lodging operations are using an increasing number of single service
products of paper, metal and plastic, metal disposable ashtray, unwoven cloth napkins, plastic
cocktail glasses, paper bath mats, paper service ware, etc. There is more waste than ever, and often
it is harder to transport for removal.

Every aspect of food service and lodging generates some type of waste which requires a
removal activity. The exact dimensions of the problems are defined by the type of waste, the amount
of waste, and the distance it must be moved.

A differentiation among types of wastes is important. Different types of waste occupy different
amounts of space per pound. Different types of waste require different handling techniques and
handling equipment and different types of waste pose health hazards or varying intensities.

Seven major types of waste encountered in food service and hospitality operations can be
identified:

 Trash consists of debris, cardboard, wood boxes, sweepings and some plastic rubber (up to 10%).
 Rubbish consist of paper, cardboard, wood, landscaping debris, and food waste up to 20 % but no
plastic or rubber.
 Refuse is approximately half rubbish and half garbage.
 Garbage consists of animal and vegetable food scraps.
 Paper waste consists of documents, cardboard folders, printed materials, and data processing
punch cards.
 Liquid waste includes sewage, drainage waters, and cooling waters that are not reused.
 Gaseous waste includes hot air from dining rooms and lodging, ventilation and cooling exhaust
fumes cooking, fumes and gases from heating and steam generation, etc. Trash presents a fire
hazard. Refuse and garbage are health hazards. Liquid waste can property Each type of waste
must be removed speedily and inexpensively in a manner that is aesthetically acceptable and
consistent with health and fire regulations.

SOLID WASTE DISPOSAL SYSTEMS

While the accumulation of solid waste in an operation can be limited by wise management and
proper purchasing, it cannot be greatly reduced. Management's real concern involves the While the
accumulation of solid waste in an operation can be limited by wise management disposal of waste.
The problem can be divided into four aspects which represent the major steps in the removal of solid
waste: (1) collection from the point of waste generation (2) a method of transportation of the waste (3)
a place of processing to (4) a removal method.
Collection of solid waste generally involves a variety of container like plastic and paper bags in racks
or cans, trash cans, waste paper cans and garbage cans.
Processing is the pivotal phase of the removal operation because it determines the form and
consequently the economics of final disposal, although disposal is possible without ang processing.
Trash bins, dumpsters (containers that dump directly into garbage trucks), and garbage cans are
unfortunately common in many restaurant and hospitality parking lots of backyards.
SANITARY LIQUID WASTE DISPOSAL
 Most plumbing is not operational concern for management. The proper plumbing sewage, and
drainage pipes for the sanitary disposal of liquid waste have generally been installed as part of the
original construction of the facility or installed during renovation Plumbing maintenance is an on-going
management concern because proper waste disposal is possible only with a functioning system.
Basic maintenance can be covered with a few simple directives:
 Cleanout cover should be removed at least twice a year and the condition of the piping
determined
 Traps (fitting placed in drainpipes to hold water used to block the passage of gas from the sewers
or drains) into the facility should be properly vented so that the water held in the trap is not blown
out of change of pressure in the drain.
 Grease traps should be periodically cleaned if they are installed between sinks and dishwashers
and the main drain.
 Vulnerable pipes should be insulated against freezing
 All leaks should be promptly fixed, but special attention should be paid sewage and drain pipes in
the area of fresh water inlet pipes.
 Pipes should be routinely inspected.
 Only approved materials should be used for repair, repair should be done only by experienced
plumbers.
 Overhead plumbing should be strapped.
 Pipes should be protected from blocking by the installation of tightly secure covers and screens.

Sometimes plumbing is a problem encountered by the operator when installing now

equipment. Garbage disposal units in pot sinks should not be connected to the traps that already
exist, but directly into sewer lines. On occasion, lines of a larger diameter must be installed to take an
increased load, or the pitch or slope of the lines to the sewers must be increased in order to
accommodate denser liquid waste.

CHAPTER 8
FOOD FLOW
LEARNING OUTCONIES:
 Describing the food product flow from the time it enters the workplace until it is served to
customers.
 Appreciating the importance of time and temperature control to food safety.
 Identifying safe and approved food sources to ensure product quality.
 Evaluating the criteria for accepting delivery of food products.
 Enumerating the guidelines in preparing, cooking, packaging food and transporting safe food.

THE FOOD PRODUCT FLOW

The flow of food describes what happens to food from the time it enters your workplace until it
is served to customers. Flow of food refers to the path from receiving through storing, preparing,
cooking, holding, serving, cooling and reheating that food follows in a food-service operation. At each
step in the flow of food through a food service establishment are general food safety procedures that
should be followed to help reduce the risk of contamination and mishandling and could consequently
lead to foodborne illness outbreaks.

THE BASICS OF FOOD SAFETY IN FOOD PRODUCTION FLOW

 Keep things clean and sanitized
 Practice good personal cleanliness.
 Wash hands thoroughly and frequently.
 Minimize the time food spends in the temperature danger zone.
 Prevent cross-contamination

TIME AND TEMPERATURE CONTROL

 Learn which food items should be checked, how often, and by whom. Then, assign duties to
foodhandlers in each area. Food held in hot holding should be checked at least every 4 hours, if
you check it every 2 hours then you have time to take corrective actions.
 Make sure that the correct tools are available. Thermometers and timers are both important
pieces of equipment to check how long food is in the temperature danger zone Thermometers
used to measure the temperature of food must be accurate to +/-2°F. Thermometers used to
measure air temperature in food-storage equipment must be accuratc to +/-3°F".
 Use good record keeping practices.
 Have a list of corrective actions in place when it is determined that food has been left in the
temperature danger zone for too long.

CROSS CONTAMINATION: HOW TO PREVENT CROSS CONTAMINATION

 Create a physical barrier.
 Assign specific equipment to each type of food separate cutting boards should be used for raw
and cooked foods.
 Clean and sanitize tools, equipment and utensils after each task.
 Create procedural barriers. Prepare raw and ready to cat foods at different times
 Purchase ingredients that require minimal preparation
 Monitoring Time and Temperature

FOOD PRODUCTION FLOW

The flow of food is the steps that food goes through from the time the food is purchased/received until
the time that it is served. If food is not handled safely at each step, contamination or bacterial growth
could occur. Three common flow charts are:
 Purchasing/Receiving - Storage - Serving
 Purchasing/Receiving - Storage - Preparation - Cooking Holding - Serving
 Purchasing/Receiving - Storage - Preparation Cooking - Cooling – Reheating - Serving
Your food safety plan should address how you will keep food safe at each step. Therefore, food
safety and standard operating procedures need to be developed for each step. The first step after
purchasing is develop procedures to determine if a food is safe upon purchase/receipt.

PURCHASING
Effective purchasing paves the way for a successful food service operation. Purchasing is a
highly skilled activity requiring knowledge of products and market conditions.
Purchasing involves obtaining the necessary foods in the right quantity of the boy quality, at
the right time, in the right place, and for the most economical price. A quality-control program in food
establishment should ensure that only foods which meet written specifications are purchased from
reputable vendors. The best purchaser considers price, supply and demand, transportation, and
storage cost before placing an order. Food
The main objectives of an effective purchasing program are to:
 buy the product that is best suited for the job.
 buy the proper quantity of the item.
 pay the right price for the item.
 deal with only reputable and dependable suppliers

Purchase specifications are important to both buyer and management. They are the guidelines
that detail the characteristics of a product, including such properties as:

 Quality grade
 Weight
 Count
 Contents
 Packaging

Specifications make the task of comparison shopping easier, since the characteristics of a
product are expressed in a common language and can be used as a basis for evaluation.

Employees purchasing food must follow these guidelines:

1. Understand regulations for specific foods:

 Purchase packaged or processed foods only from suppliers who receive their products from
licensed and reputable purveyors and manufacturers, who adhere to good manufacturing
practices.
 Fresh produce may be purchased directly from local growers as there is no inspection process for
these non-potentially hazardous foods (with exception of melons and fresh alfalfa sprouts). When
 making direct purchases, buyers should ensure packages are clean and will maintain the integrity
of the food item, as communicated through product specifications.
 Meats and fresh shell eggs may be purchased from local producers, but because these foods are
considered potentially hazardous, the products must be inspected for safety. Beef or pork that is
processed in a state inspected locker may be purchased by a foodservice operation. Poultry must
also be processed in a state inspected locker or facility. State inspection is sufficient if the food is
purchased by a foodservice within that state. These facilities are required to have HACCP plans in
place.
 Only pasteurized dairy products should be purchased for service in facilities serving the elderly.
Pasteurized shell or processed eggs should be purchased for menu items not receiving heat
treatment or not reaching 63° C. Pasteurized apple juice and cider should also be purchased for
service to elderly populations.

2. Visit approved vendors to ensure that they maintain clean warehouses.

3. Observe delivery vehicles to ensure that they are clean and temperature-controlled. ordered
4. Use written product specifications to ensure that the vendors know what is to be ordered.

The foodservice manager will:

 develop and implement written product specifications to ensure products purchased consistently
meet department expectations
 coordinate delivery times with vendors/suppliers to ensure that deliveries are made when they can
be stored immediately. Schedule receiving times when product quantity and quality can be
checked, including product temperature.
 review orders and delivery information to ensure orders and product specifications are being met
 request a written letter from all vendors indicating that they follow cither a HACCP program or
good manufacturing practices
 follow up as necessary

RECEIVING
Strict procedures should be followed when foods are received. All food should be checked for
proper conditions as it is received in the facility. When a delivery is made, i should be checked for
both quality and quantity, Food contaminated with pathogenic micro-organisms, chemicals and
foreign matters may compromise food safety. Therefore food premises should not accept food known
(or suspected to be contaminated with these substances.

Temperature and time are the two most important factors to control. Foods need to be
received and stored as soon as possible. The staff of the food service establishment should be
checking for temperatures and conditions of incoming foods.

All refrigerated foods should be put away quickly to prevent time and temperature abuse.
Frozen foods should not have large ice crystals, be discolored or dried-out. Home-canned goods
should have labels, no swelling and flawed scams, rust or dents. Never accept home-canned foods
because of the risk of botulism.

Receiving SOP's. Inspect it! Determine food quality by using your senses:
 Sight
 Touch
 Smell

Before you accept the merchandise.

Safe and Approved Food Source

The first line of defense in preventing foodborne illness is to obtain food from safe and
approved sources. Safe and approved sources are suppliers that comply with pertinent laws and
regulations. The only exception is that fresh, whole, uncut produce can come from any source,
including roadside vendors, Farmer's Market, and local gardens. Never us home prepared or home
canned food in your restaurant as it is not known if it was safely prepared.
Inspect before You Accept
Inspect foods to reduce your risk for foodborne illness and to be sure that food is safe Check delivery
vehicles for cleanliness and proper temperature control. Dirty vehicles could contaminate food. Never
accept food that has been shipped in a vehicle that has carried live animals or harmful substances. If
these vehicles must be used, they must be thoroughly washed, rinsed, and sanitized before they are
used to transport food.
Temperature-controlled vehicles must be at the proper temperature.
 Vehicles used to transport refrigerated foods must be at 410F (5°C) or colder,
 Vehicles used to transport frozen foods must be at 0oF (-18°C) or colder, and
 Vehicles used to transport hot foods must be at 1350F (57° C) or hotter.

Inspect all deliveries before you accept them. It is important to have a list of criteria that you or
your workers will use to determine if the food will be accepted or rejected. The food worker who
accepts food deliveries must be trained on how to use this criteria.

Other considerations
Shellstock is raw molluscan shellfish still in their shell. Molluscan shellfish include oysters,
clams, mussels, and scallops. Shellstock tags must remain attached to the container until the
container is empty. They must be kept on file for 90 calendar days from the date the container is
emptied.

Employees receiving food should follow these General Principles:

 Receive only one delivery at a time from approved suppliers.
 Check to make sure frozen food is solid, and does not show evidence of thawing and re-freezing
 Record the date received on the outside of cach package, and a usc-by date if applicable.
 Remove potentially hazardous foods from the temperature danger zone (5°C to 60CF) and place
in storage as quickly as possible.
 Check to ensure that refrigerated foods are received below 5°C.
 Accept only pasteurized dairy products.
 Reject potentially hazardous foods that are not at acceptable temperature, and cans with swelled
tops or bottoms, leakage, flawed seals, rust, or dents.
 Evaluate quality of products by odor, sight, and touch. Reject unacceptable products. Products
must meet specifications and quality requirements. If any foods are deemed unacceptable, they
should be rejected and put in a designated area for credit.
Receiving Frozen and Refrigerated Foods:
 Check temperature with a calibrated thermometer to assure that cold foods (especially potentially
hazardous foods - foods in which microorganisms are able to grow rapidly, often moist , high in
protein, and/or have a neutral or slightly acidic pH) are below 5°C.
 Reject, with the exception of fresh shell eggs (7°C), all foods that are supposed to be stored below
5°C and are delivered above 5°C.
 Check at random and record the temperature of three different types of food items immediately for
each delivery. Record date, employee initials, vendor, product name, and temperature of these
products in the receiving temperature log.
 Place foods in the proper storage area (cooler or freezer) quickly to avoid potential bacterial
growth. Proper cooler temperatures are 5°C or lower, Proper deep chill storage temperatures are
from -3°C to 0°C or below. Proper freezer temperatures are -17°C. Proper dry storage
temperatures are between 10°C and 21°C at 50 to 60 percent humidity.
 Use First In First Out (FIFO) inventory rotation of products in all storage areas to assure that
oldest products are used first. Products with the earliest use-by or expiration dates are stored in
front of products with later dates.
 Keep products in original packages until use.
 Thermometer
 Standardized
 Freezing point - 32°F (0°C) for cold foods
 Boiling point - 212°F (100°C) for hot foods
 Cleaned and sanitized to prevent cross contamination.

Receiving Dry Goods:

 Check dry goods for leaks, flaws, or broken packages. Dry goods should be dry, free of mold, and
free of insects. If the packages are flawed, they should be rejected and put in a designated area
for credit.
 Inspect cans for leaks, incomplete labels, dents, bulges, and other visible signs of damage. Notify
the manager if a damaged can is found
 Date boxes and cans with receiving date.
 Separate chemicals from foods.
 Check delivery invoice against the items delivered, and the purchase order.
 When damages items are found, the manager or designee should call the distributors the product
can be picked up and returned and a credit issued, or make similar arrangements with delivery
personnel. Do not accept delivery.
 Note on the invoice any items rejected.
Product Quality

 Poor food quality can be a sign that the food has been time-temperature abused.
 Reject food with an abnormal color.
 Reject meat, fish, or poultry that is slimy, sticky, or dry.
 Reject food with an abnormal or unpleasant odor.

Table 8.1 Criteria for accepting Delivery

FOOD CRITERIA TO ACCEPT DELIVERY
MEAT AND POULTRY 41°F(5°C) or colder. Obtained from an
approved source. Stamped with USDA
inspection stamp. Good color and no
odor. Packaging clean and in good
condition.
SEAFOOD 41°F(5°c) or colder. Obtained from an
approved source Good color and no off-
odors. Packaging clean and in good
condition.
SHELLFOOD 45°F (7°C) or colder. Obtained from
approved source. Clean shells closed,
and no broken shells. Shellstock tags
must be readable and attached.
CRUSTACEA 45°F (7°C) or colder. Obtained from an
approved source.
FRESH PRODUCE Clean and good condition. If produce is
cut or processed, it is at 41°F or colder.

DAIRY PRODUCTS 41°F (5°C) or colder unless labeled

otherwise. Obtained from an approved
source. Packaging clean and in condition.
All products are pasteurized.
EGGS Shell eggs at 45°F (7°c) or colder, liquid
eggs at 41°F (5°C) or colder. Shell eggs
-- Clean and uncracked, frozen, and dry
eggs- pasteurized Obtained from an
approved source.
REFRIGERATED AND FROZEN 41°F (5°C) or colder; if frozen, the
product is rock solid.
PROCESSED FOOD Packaging clean and in good condition.
Obtained from an approved source.
MAP If the product requires refrigeration, it is at
41°F (5°C) or colder. Obtained from an
approved source. Packaging clean and in
good condition. Labels can be read and
attached to the product.
CANNED FOOD Obtained from an approved source. No
swollen ends, leaks, rust, dents. Label
can be read and is attached to the
product.
DRY FOOD Obtained from an approved source
Packaging clean and in good condition.
No signs of pest infestation.
UHT Obtained from an approved source.
Packaging clean and in good condition. If
product requires refrigeration, it is at 410F
(50C) or colder. Label is attached and
can be read.
Baked Goods Baked Goods Obtained from an approved
source. Packaging clean and in good
 condition Products are not moldy.
Potentially Hazardous Hot Foods
Potentially Hazardous Hot Foods Obtained from an approved source.
Temperature at 135°F (57°c) or hotter.
Holding containers are clean and in good
condition.

Storage
Food starts to deteriorate as soon as the crop is harvested or the animal is slaughtered. The
rate of deterioration is related to the growth of spoilage bacteria and mold. Hence food should be
stored under the right environmental conditions (e.g. suitable temperature, humidity, lighting and
atmosphere) to minimize the growth of these micro-organisms and to prevent food from becoming
unsafe or unsuitable during their expected shelf-lives.
Proper storage preserves and prolongs shelf-lives of raw food materials and prevents them
from contamination by food poisoning bacteria, chemicals and foreign bodies that may finally render
the food materials or products unfit for processing or human consumption. Proper storage is one of
the essential steps for preventing food from becoming contaminated.
 All food, chemicals, and supplies should be stored in a manner that ensures quality and
maximizes safety of the food served to residents.
 Cold holding is storing food under refrigeration at 5°C or below. Refrigeration prevents food from
becoming a hazard by slowing the growth of most microbes.
 Some organisms like Listeria monocytogenes is significantly slowed but not stopped by
refrigeration.
 The walk-in refrigerator is the major cold storage area in a food service establishment. The
temperature of a walk-in refrigerator must be sufficient to adequately hold the food temperature at
5°C or below. The temperature of a walk-in refrigerator is usually colder than 5°C to compensate
the opening and closing of doors and demands of adding additional foods for storage and cooling.
 Foods need to be stored to prevent contamination. All cooked foods and foods that will receive no
further cooking should be stored above other foods. Foods need to be stored to allow enough
space for air to circulate around them.
 All canned foods and dry ingredients are stored in a designated area. Foods should not be stored
in areas such as restrooms, furnace rooms, stairwells or hallways. Foods should be stored off the
floor and in closed containers.
 Storage areas should be well ventilated and pest free. Dry storage areas can become a food
source for rodent and insects. Keeping containers closed, in sound condition and off the floor help
to keep the storage area pest free. Stock rotation is a good management practice. Foods and
chemicals need to be stored separately. Chemicals should be stored below and away from foods
to prevent chemical contamination.
 No food can be kept indefinitely. Food that is kept for a long time is likely to become spoiled and
attract pest infestation. Effective stock rotation, to ensure that first-come is used first, is essential
to avoiding spoilage and preventing pest infestation. In addition, good stock rotation has the
advantage of helping to keep the correct levels of stock.

Types of Storage
 Refrigeration
 Freezer
 Dry Storage
Employees who receive and store food maintain the storage areas, including dry refrigerated,
and freezer storage, by following these steps:
Storage upon Receiving:
 Place foods in the proper storage area (refrigerator or freezer) quickly to avoid bacterial growth.
 5°C or lower - refrigerator temperatures
 -3°C to 0°C or below - deep chill storage temperatures
 -17°C or below - freezer temperatures
 10°C to 21°C at 50 to 60% humidity - dry storage temperatures
 Place foods into appropriate storage areas immediately upon receipt in the following order:
 Refrigerated foods - Store foods in designated refrigerators. If food products are stored together in
a refrigerator, they should be placed on shelves in the following order:
 Frozen foods
 Dry foods

Table 8.2 Proper Stacking of Food

Prepared or ready-to-eat foods Top shelf
Fish and seafood items
Whole cuts of raw beef
Whole cuts of raw pork
Ground or processed meats
Raw poultry Bottom shelf

 Keep all food items on shelves that are at least 6" above the floor to facilitate air circulation and
proper cleaning.
 Store food out of direct sunlight.
 Place chemicals and supplies in appropriate storage areas, away from food.
 Rotate goods when placing them in storage by placing the new items behind the old items to
ensure that the older items are used first (First In, First Out inventory rotation).
 Make sure all goods are dated with receiving date and use-by date.
 Store food in original container if the container is clean, dry, and intact. If necessary,
repackage food in clean, well-labeled, airtight containers. This can also be done after a
package is opened. Food is NEVER put in chemical containers and chemicals are NEVER
placed in food storage containers.
 Store potentially hazardous foods no more than 7 days at 5°C from date of preparation.
 Store pesticides and chemicals away from food handling and storage areas. They must be
stored in original, labeled containers.

To ensure product freshness and quality, use the First In, First Out inventory method! Storage Don'ts.
Do Not Store Food:
 In toilet rooms
 In locker areas
 In mechanical rooms
 Under piping
  Under sewage lines
 Among chemicals
 With personal items.

Chemical Storage
Most chemicals are poisonous and must be properly labeled and stored away from:
 Food items
 Single-service items
 Utensils
 Equipment
 Paper goods

Storeroom Sanitation:
 Maintain clean and uncluttered storage areas. Storage areas should be positioned to prevent
contamination from areas where garbage is stored.
 Dispose of items that are beyond the expiration or use by dates.
 Store all items on shelves that are at least 6" above the floor to facilitate air circulation and
proper cleaning.
 Check for signs of rodents or insects. If there are signs of the presence of rodents or insects,
notify the foodservice manager.

Temperature Control:
 Check the temperature of all refrigerators, freezers, and dry storerooms at the beginning of
each shift. This includes both internal and external thermometers, where appropriate.
 Refrigerator temperatures should be between 2°C and 5°C.
 Freezer temperatures should be between -23°C and -17°C.
 Storeroom (dry storage) temperatures should be between 10°C and 21°C.
 Record temperatures on the appropriate temperature log and initial.
 Take corrective actions if temperatures are out of the recommended range.
 Do not overload refrigerated storage areas, as this prevents air flow and makes the unit work
harder to stay cold.
 Use caution when cooling hot food in the refrigerator, as this warras the unit and can put other
foods into the temperature danger zone.
 Keep units closed as much as possible to maintain proper temperatures.
 Defrost all units on a regular schedule to aid in proper maintenance and air circulation.

The foodservice manager will:

 Check logs and temperature of storage rooms, freezers, and refrigerators.
 Review logs to make sure there are no temperature deviations.
 Document all corrective action taken on the appropriate forms.
 File logs with HACCP records.
Thawing Food
Freezing prevents bacteria from growing, but does not kill them. Improper thawing (e.g.
thawing at room temperature) provides an opportunity for food poisoning bacteria grow to harmful
numbers and / or produce toxins. It should be noted that the food safety risk of thawing frozen ready-
to-eat potentially hazardous food is much higher than thawing frozen raw potentially hazardous food
that will be cooked or subject to other pathogen-reduction steps before eating.
All foods will be thawed using appropriate practices to ensure food safety. Thawing foods may
take several hours or days depending on the size of the food item being thawed. Thawing must be
done so that the risk of cross-contamination is reduced, and the time that potentially hazardous food
is in the temperature danger zone (5°C to 60°C) is kept to minimum.
Steps for thawing food include:
 Use one of the three acceptable methods for thawing food:
 Thaw food in the refrigerator at 5°C or below. NEVER thaw food at room temperature.
 Thaw food needed for immediate service under potable running water at 21°C or lower.
Prepare the product within 4 hours of thawing.
 Thaw the product in the microwave if product will be cooked immediately as part of the cooking
process.
 Use the lowest shelf in the cooler for thawing raw meat to prevent cross-contamination and
separate raw products from cooked and ready-to-eat products.
 Do not refreeze thawed food, unless they are first cooked or processed.

The foodservice supervisor will:

 Review procedures to assure they are done correctly.
 Take corrective action as necessary.
 Follow-up as necessary.

Preparation of Safe Food

The preparation and service of foods can involve one or more steps. Regardless of how many steps
may be involved in food production and service, foodborne illness prevention requires effective food
safety measures that ensure good personal hygiene and avoid cross-contamination and temperature
abuse.
During preparation, an important technique that can be used to promote safety is “small batch”
preparation. Food preparation is usually done at room temperature. This is several degrees into the
temperature danger zone. Therefore, one must limit the amount of time the food is in the danger zone
by working in small and manageable amounts of potentially hazardous ingredients.
Guidelines in preparing safe food:
 Start with clean, wholesome foods from reputable purveyors. Whenever applicable, buy
government-inspected meat, dairy, and egg products.
 Handle as little as possible. Use tongs, spatulas, or other utensils instead of hands whenever
possible
 Use clean, sanitized equipment and worktables. Clean and sanitize cutting surfaces and
equipment after handling raw poultry, meat, fish, or eggs and before working on another food
 Clean as you go. Do not wait until the end of the workday.
 Wash raw fruits and vegetables thoroughly.
 When bringing foods out of refrigeration, do not bring out more than you can process is an
hour.
 Keep foods covered whenever possible unless in immediate use.
 Do not mix leftover with freshly prepared foods.
  Chill all ingredients for protein salads and potato salads before combining.

Keeping Food Out of the Temperature Danger Zone

Anytime that food temperatures are in danger zone, bacterial growth can occur. The danger
zone is the range between 5°C and 60°C.
 Limit the time food is in the temperature danger zone. Remember, from receiving to service,
food should not be in the zone more than four hours total.
 Use your food thermometer to take temperatures. Most menu items have a specific time and
temperature requirements for cooking. Insert the thermometer in different areas of the product,
especially the thickest part. Remember, the temperature of the equipment (stove, oven, steam,
table etc.) is not the best temperature to check.
 Use batch cooking (preparing food in small amounts).
a) Thaw only what you need, and keep it refrigerated.
b) Work only with the amount you can prepare in less than four hours. Return food to the
refrigerator if you have to leave to do something else.
c) Cook the food as close to serving time as possible.

Food Thermometers
Food thermometers should be used frequently to maintain food temperature control. They can
measure internal temperature ranging from -180C to 1040C. Food temperatures should be checked
with thermometer regularly. Foods used in outdoors service or in excessively warm room will require
more frequent checking. The food-service operator may also want to record the temperature readings
in a log. This can be very helpful should safe food temperature issue arise at a later time.
The following are the most commonly used thermometers:
 Bimetal Instant Read most common food thermometer
 Thermocouple
 Bimetal-Oven Safe
 Digital
 Infrared
 Oven Thermometer

Preparing Cold Food

Temperatures of all cold food will be taken during preparation to ensure safety of all food
served. All food will be prepared using appropriate practices and procedures to ensure safety and
sanitation.

Employees preparing cold food should:

Take temperatures:
 Use a calibrated thermometer to take the temperatures of potentially hazardous food products.
 Wipe the thermometer stem with alcohol wipes prior to and after taking the temperatures of
food; or wash stem, rinse, and sanitize.
 Record temperatures in the Service Temperature Record.

Prepare cold foods:

  Pre-chill ingredients for food served cold (sandwiches and salads) to below 5°C before
combining
 Discard thawed potentially hazardous foods that have been above 5°C for more than four
hours.
 Discard cold potentially hazard foods after four hours if they have not been properly held below
5°C.

Maintain food contact surfaces:

 When possible, use color-coded cutting boards for all products. Red for raw meat, green for
vegetables or fruits, and yellow for raw poultry.
 Food contact surfaces should be smooth, easily cleaned and sanitized, and of appropriate
material.
 Clean and sanitize all food contact surfaces prior to and after use. Cleaning and sanitizing
steps need to be done separately in order to be effective.

Prepare foods.
 Prepare food at room temperature in two hours or less, or the food item should be returned to
the refrigerator. Total time of food at room temperature shall not exceed four hours.
 Prepare raw products away from other products.
 Clean and sanitize all surfaces, cutting boards, and utensils that have been used in the
preparation of raw meats, poultry, and fish prior to using for fruits, vegetables, and ready to eat
food.

Cooking Food
It is generally recognized that cooking is to increase the palatability and to tenderize and
change the character of food. Cooking, however, is also important in destroying organisms that may
cause diseases. Proper cooking is often the critical control point in preventing foodborne disease
outbreaks.
All foods will be cooked using appropriate practices and procedures to ensure safety This
includes properly cooking foods to required internal temperatures and taking and recording
temperatures.
Cooking is the thermal heating of foods at sufficient temperature over time to kill
microorganisms in the food. Cooking requirements are based on the biology of pathogens. Different
species of microorganisms have different susceptibilities to heat.
To effectively eliminate pathogens, there are a number of factors to consider the level of
pathogens in the raw product and the initial temperature of the food and the bulk of the food. Another
factor to consider, to kill the pathogenic organisms in food, cooking must heat all parts of the food to
the required temperatures.
Food characteristics also contribute to the lethality of cooking temperatures. Heat penetrates
different foods at different rates. High fat content reduces the lethality of heat. High humidity in the
cooking container or the moisture content of the food aid the lethality of heat.
Employees involved in the production of food must complete the following steps:
Prepare hot foods:
  Cook hot foods to these minimum end-point temperatures or higher. Avoid over-cooking. Use a
calibrated thermometer to check product temperature in thickest part of the item.
 Take end-point cooking temperatures.
 Reduce holding time of foods before serving by using batch cooking.
 Allow temperature of cooking equipment to return to required temperatures between batches.
 Do not use hot holding equipment to cook or reheat foods.
 Expose food ingredients to room temperature for two hours or less, or food item should be
returned to the refrigerator. Total time of food at room temperature shall not exceed four hours.
 Prepare products that will not be cooked or heated away from other products.
Food type Minimum Internal Temperature at
minimum time before serving
Poultry 74°C for 15 seconds
Stuffing, stuffed meats, casseroles, and 74°C for 15 seconds
other dishes combining raw and cooked
foods
Potentially Hazardous Foods cooked in 74°C; let food stand for 2 minutes after
microwave cooking, stir during cook process
Ground or flaked meats 68°C for 15 seconds
Pork 63°C for 15 seconds
Beef and pork roasts 63°C for 4 minutes
Beef steaks veal, lamb 63°C for 15 seconds
Commercially raised game animals 63°C for 15 seconds
Fish and foods containing fish 63°C for 15 seconds
Shell eggs (for immediate service) 63°C 63°C for 15 seconds
for 15 seconds (if it is not fully cooked use
pasteurize eggs)
Vegetables (canned, frozen, fresh) 57°C for 15 seconds, held above 57°C
Ready-to-eat commercially processed 57°C for 15 seconds, held above 57°C
and packaged foods
Table 8.3 Cooking Guidelines
Take temperatures:
 Use a calibrated thermometer to take the temperatures of all potentially hazardous food
products, each batch.
 Wipe the thermometer stem with alcohol wipes prior to and after taking the temperatures of
each food; or wash stem, rinse, and sanitize. Open the sanitizer package with clean hands.
 Take temperatures in the thickest part of a food item (usually the center). Two readings should
be taken in different locations to assure thorough cooking to the appropriate end-point
temperature.
 Record the end-point cooking temperature on the Cooked Food Temperature Log.

The foodservice manager will:

 Review logs daily to ensure that temperatures and corrective actions are being met and take
corrective action as necessary.
 Follow up as necessary and file logs with HACCP records.

Holding Food
 Once a food is heated or cooked, the food must be maintained at a temperature to limit the
growth of bacteria. The correct hot holding temperature is 60°C. The potential for growth of
pathogenic bacteria increases once a food is reheated than the potential in raw foods. The spoilage
organisms that may be present in raw foods inhibit the growth of pathogenic organisms by
competition. Once a food is cooked, these spoilage organisms are reduced.
All hot food will be held hot (above 60'C) and cold food will be held cold (below 5°C) Keep Hot
food HOT and cold food COLD. Temperatures of food will be taken routinely to ensure that proper
temperatures are maintained through holding to ensure the safety of the food served to children. Any
conflict between food quality and food safety must always be decided in favor of food safety. When in
doubt about the safety of food, throw it out.

Employees involved in the production or service of food must:

Holding Hot Food:
 Prepare and cook only as much food as is needed (i.c. Use batch cooking).
 Use hot-holding equipment that can keep hot food at 57-60°C or higher.
 Follow manufacturer's instructions in using hot-holding equipment. [NOTE: Customize your
SOP by including instructions. For example, you may need to indicate that the steam table
wells need to be filled with hot water and at what level.]
 Keep foods covered to retain heat and to keep contaminants from falling into food.
 Measure internal food temperatures at least every two hours using a probe thermometer.
Record temperatures in a food temperature log. If températures are below 60 °C then reheat to
74 °C.
 Discard hot food after four hours if they have not been properly held at or above 60°C.
 Do not mix freshly prepared food with food being held for service. Do not add raw food to
cooked food.
 Stir food.

Holding Cold Food:

 Use cold-holding equipment that can keep cold foods below 5°C.
 Measure internal food temperatures at least every two hours using a probe thermometer.
Record temperatures in a food temperature log. If temperatures are above 5°C, then
refrigerate.
 Protect cold food from contaminants with covers or food shields.
 Discard cold potentially hazard foods after four hours if they have not been properly held below
5°C.
 Place cold food in pans or on plates first, never directly on ice. The only exceptions are whole
fruits and vegetables that will be washed after holding.
 Ice used on a display should be self-draining. Wash and sanitize drip pans after each use.
The foodservice manager will:
 Review logs daily to ensure the temperatures and corrective actions are being met.
 Follow up as necessary.
 File temperature logs with HACCP records.

Cooling Food
 Cooling is a process of removing heat from food quickly enough to prevent microbial growth
One method is done by placing foods in shallow containers no deeper than 2 inches and leaving them
uncovered until cold, 5°C or below.

When potentially hazardous food is cooled for an extended period, the food is subject to the
growth of a variety of pathogenic micro-organisms. Bacteria grow ideally between 21 - 49°C. (The
human body temperature falls in this range). The longer the time the food is allowed to be held in this
range, the greater the risk of microbial growth. Excessive time for cooling potentially hazard food has
consistently been identified as one of the leading contributing factors to foodborne illness.

When cooked food will not be served right away (or is left over and can be saved), it must be
cooled as quickly as possible to prevent microbial growth. Temperatures will be taken during the
cooling process to make sure that time and temperature standards are met to ensure the safety of
food served to residents.

There are two acceptable methods of cooling foods outlined below. Employees involved in the
cooling process of food must observe the following procedures:

One-stage (four hour) method:

 Cool hot cooked food from 57°C to 5°C within four hours using appropriate procedure.
 Take temperatures at four hours to make sure that the appropriate temperature is reached.
 Reheat food to above 740C if food has not cooled to 5°C in four hours.
Two-stage method (+recommended in the FDA Food Code)
 Cool hot cooked food from 57°C to 21°C or lower within two hours, and then cool down to 5°C
or lower within an additional four hours, for a total cooling time of six hours, using appropriate
procedure.
 Take temperatures at the two and six hour intervals to make sure that appropriate
temperatures are reached.
 Reheat food to above 740C if food has not cooled to 5°C in four hours.
*NOTE: The reason that the two-stage method allows six hours to cool is that in the first no hours
of cooling the food is passed through the most dangerous part of the temperature danger zone,
where the growth of microorganisms is ideal.

Factors that affect how quickly foods will cool down:

 Size of the food being cooled - the thickness of the food or distance to its center plays the
biggest part in how fast a food cools.
 Density of the food - the denser the food, the slower it will cool. Chili will take longer than
chicken noodle soup.
 Container in which a food is stored - stainless steel transfers heat from food faster than
plastic. Initially loosely wrap food items. Shallow pans allow the heat from food to disperse
faster than deep pans.
 Size of container.
 Food may not move through the temperature danger zone fast enough if the food is still hot
when placed in the refrigerator or freezer or kept in bulk. The hot food may also raise the temperature
of surrounding food items, placing them in the temperature danger zone (5°C - 60°C).

Listed below are a few methods than can be used to cool foods more quickly. The methods
can be used alone or in combination in order to cool foods quickly.

Methods for cooling foods:

 Reduce the quantity of the food being cooled. Cut large food items into smaller pieces or divide
large containers of food into smaller containers.
 Use blast chillers or tumble chillers to cool food before placing it into refrigerated storage.
 Use ice-water baths. Divide cooked food into shallow pans or smaller pots then place them in
ice water and stir food items frequently.
 Add ice or water as an ingredient. This works for foods that contain water as an ingredient,
such as a soup or stew. The recipe can initially be prepared with less water than is required.
Cold water or ice can be added after cooking to cool the product and to provide the remaining
water required in the recipe.
 Use a steam-jacketed kettle as a cooler. Run cold water through the jacket to cool the food in
the kettle.
 Stir foods to cool them faster and more evenly. Ice paddles (plastic paddles that are filled with
water and frozen) and chill sticks can be used to stir foods through the cooling process. Stirring
food with these cold paddles chills foods very quickly.
The foodservice manager will:
 Review logs daily to ensure temperatures and corrective actions are being met.
 Follow up as necessary. File temperature logs with HACCP records

Service Temperatures
Temperatures of all hot and cold foods are taken during service to ensure that foods are
maintained at appropriate temperatures to ensure the safety of food served.

Employees who will be setting up the service carts and serving food must follow these
procedures:
 Use a calibrated thermometer to take temperatures of food products at time of service.
 Wipe the clean thermometer stem with a new alcohol wipe prior to taking the temperature of
any food item.
 Take temperatures of all hot potentially hazardous foods as soon as they are put on the
service cart or just before service. Take temperatures of all cold potentially hazardous foods as
they are put on the service cart or just before service. Take temperature of milk before taking
to rooms.
 Record temperatures on the Service Temperature Log and initial.
 Check to make sure that all temperatures are within the critical limits:
 Hot foods are above 60°C
 Cold foods are below 5°C
  Take corrective action, if needed. If hot foods are below 60°C, they must be reheated to above
74°C before putting on the service cart.
 Take corrective action, if needed. If cold foods are 5°C or above, they must be chilled to below
5°C.

The foodservice supervisor will:

 Check the logs on a daily basis to ensure that they are completed and that the temperatures
are appropriate.
 Review the log to see if there were temperature deviations.
 Check corrective action taken to determine if it was appropriate.
 Follow-up as necessary.
 File the logs in the HACCP file located in the main office.
Service of Food
` Once food has been prepared for serving, it will no longer undergo any heat treatment. It is
therefore important not to recontaminate food by practicing proper serving methods that would assure
the consumers of safe and hygienic food. The most common food safety problems found during
service or display of food are (a) inadequate temperature control and (b) cross-contamination.
Employees involved in the service of food must observe the following procedures:
Cleaning and sanitation:
 Clean the area on and around the service line, using warm soapy water and clean cloths.
Thoroughly rinse area after cleaning.
 Sanitize the area on and around the service line, using an approved sanitizer.
 Wipe down area before service begins, and as needed throughout service.
 Cloths used for cleaning food spills should not be used for anything else.

Service utensils/serviceware:
 Store utensils properly with the handle extended above the container, or on a clean, sanitized
food-contact surface.
 Use serving utensils with long handles to keep hands away from the food item.
 Clean and sanitize utensils before using them, and use separate utensils for each food item.
 Handle glassware and dishes properly.
 Hold flatware and utensils by the handles.

Practice good personal hygiene:

 Wash hands before handling place settings or food.
 Do not touch cooked or ready-to-eat foods with bare hands. Always use gloves or utensils.
 Wash hands between each different task. For example, if the same employee is loading dirty
dishes and taking out clean dishes, a thorough handwashing must be done between the two
tasks. Hand dips are not used.

Service:
 Take temperatures of foods at the beginning of each service period.
 Record temperatures on Service Temperature Record and initial.
  Take temperatures of foods when changing pans of food to assure proper serving
temperatures are achieved.

The foodservice manager will:

 Supervise employees to ensure that proper service techniques are being followed.
 Review logs daily to ensure temperatures and corrective actions are being met.
 Follow up as necessary
 File logs with HACCP records.

Reheating Food (Leftovers)

Reheating is the thermal process to heat foods that have been previously cooked and cooled
in a food service establishment. Proper reheating can eliminate a major portion of pathogens. Proper
reheating is heating a food to 165°F within two hours
The more a food is processed, the greater the risks. When food is held, cooled and reheated,
there is an increased risk from contamination caused by personnel, equipment procedures and other
factors. When food is cooked and cooled the product goes through the danger zone (optimal
temperature range for microorganisms to grow) several times which also increase the risks.
To reheat foods quickly:
 Reheat in small quantities
 Use preheated ingredients
 Stir foods frequently

Employees reheating food should:

 Remove leftover food from the freezer/refrigerator.
 Check the temperature of the food to make sure it is lower than 5°C using a calibrated
thermometer
 Reheat food so that all parts of the food reach a temperature reading of 74°C for 15 seconds
using an oven, stove, or steamer. The goal is to take the food through the temperature danger
zone (5°C -60°C) as quickly as possible. Record reheated temperature. Discard food that has
not reached this temperature within two hours.
 Serve the food immediately, or place the food in a steam table or in a pre-heated hot cart and
recheck temperature to make sure temperature is at or above 60°C.
 Check the temperature of the food before serving if the food has been held.
 Discard any potentially hazardous foods held in the temperature danger zone (5°C to 60°C) for
more than four hours.

The foodservice supervisor will:

 Check the temperature of randomly selected reheated items to be certain 74°C was achieved
and that the product is held at 60°C or higher
 Review temperature logs to assure proper reheating temperatures are achieved.
 Follow-up as necessary and document corrective action.
 File temperature logs with HACCP records.

Food Packaging
 In addition to prolonging shelf-life, retaining quality and nutritional values as well as providing a
water vapour / gas barrier, packaging is important for preventing food from being contaminated with
chemicals, physical matters and bacteria.
Packaging materials should not endanger the safety and suitability of the food in contact with
them. They should be suitable for the food to be packed, non-toxic, durable and clean. Chemicals
from packaging materials should not migrate into the food; and if migration occurs, there should be no
known toxic effects to consumers.
Packaging materials may contaminate food if they are not clean. They should thus be kept in
their original packages and stored in clean areas where they are not exposed to risks of
contamination.
 Packaging materials should be appropriate for the food to be packed and sufficiently durable to
withstand the conditions of processing, storage and transportation
 Packaging materials should not pose a threat to the safety of the food to be packed.
 Packaging materials and design should provide adequate protection for the food to be packed
to minimize contamination and prevent damage.
 Packaging of food should be carried out under hygienic conditions to protect the food from
risks of contamination.
 Packaging and wrapping of food should be carried out under hygienic conditions by staff with
appropriate training in food hygiene and food safety
 Packaging materials should be stored and handled under hygienic conditions to minimize the
risks of contamination and deterioration

Transportation of Foods from Central Kitchens to Satellite Locations (Temporary and Mobile
Food Facilities)

The popularity of temporary and mobile facilities such as street fairs, festivals, catering, food
sampling, and mobile arts increased rapidly during the past decade. The public patronizes these
events in increasing numbers. In addition to the opportunity for community involvement, commercial
and non-commercial organizations are finding it profitable to sell food at temporary facilities.

Transportation of food provides a significant opportunity for contamination and spoilage.

Contamination may occur if food is carried in dirty or inappropriate containers or vehicles, or is
transported together with toxic chemicals, or is inadequately covered or packaging becomes
damaged by poor handling. A further risk is introduced if potentially hazardous food is transported
under ambient temperature that encourages growth of pathogenic bacteria.

All foods will be transported in a manner that ensures quality and safety of food. Protecting the
food and food preparation equipment from contamination is the function of the structure. A temporary
food stand should have:
 an overhead covering
 an enclosed area except for the serving windows and an entry door.
 a source of hot and cold potable running water for handwashing, cleaning, and sanitizing.

Employees involved in the production and/or transportation of food from a central or regional kitchen
to a satellite location must be responsible for both the safety and sanitation of food handled Steps
include:
 Preheating holding equipment.
  Use calibrated thermometers to take temperatures of food.
 Calibrate thermometers weekly or sooner if dropped.
 Record temperature and time in Temperature Log and initial.

Employees at Central or Regional Kitchen:

 Take temperature of food when it leaves the central kitchen. Hot foods should able to above
60'C and cold food should be below 5°C.
 Record temperatures in log and initial
 Take temperature of food when it is returned from a satellite location.
 Discard cold foods that are above 5°C.
 Discard hot foods that are not above 60°C.
 Chill hot foods that are above 60°C. The product must be cooled to 21°C in two hours from the
last 60°C reading. If that is not possible, dispose of food. If it is possible, cool to 21°C in two
hours and to 5°C or below in four additional hours.
 Record temperature in log and initial.
 Record the product name, date, temperature, and time.
 Place chilled food in freezer.

Employees a t Satellite Location:

 Take temperature of food when it arrives at the satellite location and record.
 Check temperature of food on serving lines every two hours, or more often if temperatures are
near the temperature danger zone C - 60°C).

The foodservice manager will:

 Review logs daily to ensure the temperatures and corrective actions are being met.
 Follow up as necessary.
 File temperature logs in HACCP file.

CHAPTER 9

HAZARD ANALYSIS AND CRITICAL CONTROL POINT

LEARNING OUTCOMES
  Analyzing hazards and critical control point in preventing the occurrence of potential food
safety problems.
 Defining key terms used in the Hazard Analysis and Critical Control (HACCP) system.
 Tracing the history of the HACCP system.
 Assessing the advantage, disadvantages as well as the highlights of the HACCP system.
 Developing a HACCP plan in accordance to the food production flow.

The acronym HACCP stands for Hazard Analysis and Critical Control Point, which is T a prevention-
based food safety system. HACCP systems are designed to prevent the occurrence of potential food
safety problems. This is achieved by assessing the inherent risks attributable to a product or a
process and then determining the necessary steps that will control the identified risks.

Essentially, HACCP is a system that identifies and monitors specific foodborne hazards --
biological, chemical, or physical properties -- that can adversely affect the safety of the food product.
This hazard analysis serves as the basis for establishing critical control points (CCPS). CCPs identify
those points in the process that must be controlled to ensure the safety of the food. Further, critical
limits are established that document the appropriate parameters that must be met at each CCP.
Monitoring and verification steps are included in the system, again, to ensure that potential risks are
controlled. The hazard analysis, critical control points, critical limits, and monitoring and verification
steps are documented in a HACCP plan. Seven principles have been developed which provide
guidance on the development of an effective HACCP plan.

HACCP represents an important food protection tool. HACCP is not something limit- ed to food
franchises or chains. The concept can be applied by small independents as well as national or
regional companies and can be integrated into the recipes and standard operating procedures of any
size establishment. Employee training is key to successful implementation. Employees must learn
which control points are critical in an operation and what the critical limits are at these points, for each
preparation step they perform. Establishment management must also follow through by routinely
monitoring the food operation to verify that employees are keeping the process under control by
complying with the critical limits.

Definitions

Many terms are used in discussion of HACCP that must be clearly understood to effectively
develop and implement a plan. The following definitions are provided for clarity:
 Acceptable level means the presence of a hazard which does not pose the likelihood of
causing an unacceptable health risk
 Control point means any point in a specific food system at which loss of control docs not lead
to an unacceptable health risk.
 Critical control point, as defined in the Food Code, means a point at which loss of control may
result in an unacceptable health risk
 Critical limit, as defined in the Food Code, means the maximum or minimum value to which a
physical, biological, or chemical parameter must be controlled at a critical control point to
minimize the risk that the identified food safety hazard may occur
 Deviation means failure to meet a required critical limit for a critical control point
  HACCP plan, as defined in the Food Code, means a written document that delineates the
formal procedures for following the HACCP principles developed by The National Advisory
Committee on Microbiological Criteria for Foods.
 Hazard, as defined in the Food Code, means a biological, chemical, or physical property that
may cause an unacceptable consumer health risk.
 Monitoring means a planned sequence of observations or measurements of critical limits
designed to produce an accurate record and intended to ensure that the critical limit maintains
product safety. Continuous monitoring means an uninterrupted record of data.
 Preventive measure means an action to exclude, destroy, eliminate, or reduce a hazard and
prevent recontamination through effective means
 Risk means an estimate of the likely occurrence of a hazard.
 Sensitive ingredient means any ingredient historically associated with a known microbiological
hazard that causes or contributes to production of a potentially hazardous food as defined in
the Food Code
 Verification means methods, procedures, and tests used to determine if the HACCP system in
use is in compliance with the HACCP plan.

History

The application of HACCP to food production was pioneered by the Pillsbury Company with
the cooperation and participation of the National Aeronautic and Space Administration (NASA), Natick
Laboratories of the US Army, and the US Air Force Space Laboratory Project Group. Application of
the system in the early 1960's created food for the United States' space program that approached
100% assurance against contamination by bacterial and viral pathogens, toxins, and chemical or
physical hazards that could cause illness or injury to astronauts. HACCP replaced end-product testing
to provide food safety assurance and provided a preventive system for producing safe food that had
universal application.

In the succeeding years, the HACCP system has been recognized worldwide as an effective
system of controls. The system has undergone considerable analysis, refinement, and testing and is
widely 19 accepted in the United States and internationally.

Advantages of HACCP
FDA is recommending the implementation of HACCP in food establishments because it is a system of
preventive controls that is the most effective and efficient way to ensure that food products are safe.
A HACCP system will emphasize the industry's role in continuous problem solving and prevention
rather than relying solely on periodic facility inspections by regulatory agencies.
HACCP offers two additional benefits over conventional inspection techniques. First, it clearly
identifies the food establishment as the final party responsible for ensuring the safety of the food it
produces. HACCP requires the food establishment to analyze its preparation methods in a rational,
scientific manner in order to identify critical control points and to establish critical limits and monitoring
procedures. A vital aspect of the establishment's responsibility is to establish and maintain records
that document adherence to the critical limits that relate to the identified critical control points, thus
resulting in continuous self-inspection. Secondly, a HACCP system allows the regulatory agency
comprehensively determine an establishment's level of compliance. A food establishment's use OF
HACCP requires development of a plan to prepare safe food. This plan must be shared with the
regulatory agency because it must have access to CCP monitoring records and other data necessary
to verify that the HACCP plan is working. Using conventional inspection techniques, an agency can
only determine conditions during the time of inspection which provide a "snapshot" of conditions at
the moment of the inspection. However, by adopting a HACCP approach, both current and past
conditions can be determined. When regulatory agencies review HACCP records, they have, in
effect, a look back through time. Therefore, the regulatory agency can better ensure that processes
are under control.
Traditional inspection is relatively resource-intensive and inefficient and is reactive rather than
preventive compared to the HACCP approach for ensuring food safety. Regulatory agencies are
challenged to find new approaches to food safety that enables them to become more focused and
efficient and to minimize costs wherever possible. Thus, the advantages of HACCP-based
inspections are becoming increasingly acknowledged by the regulatory community.
HACCP Highlights
 Mandatory for export from certain sectors of food industry to some countries
 Pro-active system for assuring safe production of foods
 Emphasizes prevention rather than inspection
 Addresses all types of Hazards-Microbiological, Physical and Chemical
 Can be integrated into a more general quality assurance plan
 Can be implemented in tiny, small, medium and large scale enterprises

HACCP begins with a concept called the flow of food. This term means the path from receiving
through storing, preparing, cooking, holding, serving, cooling, and reheating that food follows in a
food service operation. Foods are at risk during these different phases.

At each flow of food, food workers need to know what standards have to be met, what
procedures to follow to meet standards, and what to if they are not met. To reduce the chances of
making mistakes these standards and procedures are written out. Do possible, they should be
included in the operation’s recipes.

Procedures must be rechecked when any of the following occurs:

 Recipe changes
 Cooking equipment changes
 Preparation changes for quantity
For HACCP plans to be effective, the unique features of a food operation must be taken into count.
This is because, while the process or steps in preparing foods are often the same, every food
service/catering business is different. There will be different food safety hazards caused by factors
such as:
 Menus
 Working space available
 Type and condition or equipment used
 Selection and supply of ingredients used
 Process used for preparation, production, and service of foods
 Standards of good hygienic practices employed in the operation.

Benefits of a HACCP based Food Safety Management System

Food safety management systems built in accordance with the principles of HACCP have a clearly
defined structure.
 Process Based System: Business will benefit from a clear definition of processes and
procedures, Effective communication and continual process improvement are the cornerstones
of a functioning management system.
 Customer and Consumer Confidence: A controlled food operating environment and
effectively implemented and applied food safety system will improve customer and consumer
confidence in the safety of food.
 Risk Management: It uses a systematic approach covering all aspects of food production from
raw materials, processing, distribution, point of sale to consumption and beyond. It moves a
company from a solely retrospective end product testing and sampling approach towards a
preventative approach that is designed to reduce product losses and liabilities.
 Management Responsibility: It enables management throughout a business to demonstrate
their commitment to the production and supply of safe products and within facility
environments that are favorable for the production or supply of safe food.
 Relationship Improvement: To enhance the relationships between organizations in the food
chain, customers and enforcement agencies.
 Records: Record-keeping enables a more efficient and effective government and customer
over sight, and allows investigators to see how well a firm is complying with food safety laws
over a period of time rather than how well it is doing on any given day. The documentation
within a food safety system facilitates the inspection activities of food inspectors.
 Legal Protection: It has been widely accepted that HACCP based systems present the food
industry with the most effective management tool to enable the production and supply of safe
food. As such, the adoption of this approach can offer a legal defense in the event of an
outbreak of food borne diseases
 Trading Benefit: HACCP based approaches are a benefit to companies seeking to meet
customer and legal requirements whether in the domestic or for the export market.
 Alignment with other management systems: HACCP based food safety management
systems can be combined with other management systems such as ISO 9001:2000. This
combination provides a hazard analysis approach with prerequisite programmes along with a
framework to manage a food safety system.
Prerequisite Programs
The production of safe food products requires that the HACCP system be built upon a solid
foundation of prerequisite programs. Each segment of the food industry must provide the conditions
necessary to protect food while it is under their control. This has traditionally been accomplished
through the application of cGMPs (Good Manufacturing Practices). These conditions and practices
are now considered to be prerequisite to the development and implementation of effective HACCP
plans.
Education and Training
The success of a HACCP system depends on educating and training management and
employees in the importance of their role in producing safe foods. This should also include
information the control of foodborne hazards related to all stages of the food chain. It is important to
recognize that employees must first understand what HACCP is and then learn the skills necessary to
make it function properly. Specific training activities should include working instructions and
procedures that outline the tasks of employees monitoring each CCP.
 Management must provide adequate time for thorough education and training. Personnel must
be given the materials and equipment necessary to perform these tasks. Effective training is an
important prerequisite to successful implementation of a HACCP plan.
Developing a HACCP Plan
The format of HACCP plans will vary. In many cases the plans will be product and process
specific. However, some plans may use a unit operations approach. Generic HACCP plans can serve
as useful guides in the development of process and product HACCP plans; however, it is essential
that the unique conditions within each facility be considered during the development of all
components of the HACCP plan.
In the development of a HACCP plan, five preliminary tasks need to be accomplished before
the application of the HACCP principles to a specific product and process. The five preliminary tasks
are given in Figure 1.
Preliminary Tasks in the Development of the HACCP
Plan Assemble the HACCP Team
?
Describe the Food and its Distribution
?
Describe the intended Use and Consumers of the Food
?
Develop a Flow Diagram Which Describes the Process
?
Verify the Flow Diagram

Assemble the HACCP Team

The first task in developing a HACCP plan is to assemble a HACCP team consisting of individuals
who have specific knowledge and expertise appropriate to the product and process. It is the team's
responsibility to develop the HACCP plan. The team should be multi-disciplinary and include
individuals from areas such as engineering, production, sanitation, quality assurance, and food
microbiology. The team should also include local personnel who are involved in the operation as they
are more familiar with the variability and limitations of the operation. In addition, this fosters a sense
of ownership among those who must implement the plan.
Due to the technical nature of the information required for hazard analysis, it is recommended
that experts who are knowledgeable in the food process should either participate in or verify the
complete- ness of the hazard analysis and the HACCP plan. Such individuals
should have the knowledge and experience to correctly: (a) conduct a hazard analysis; (b) identify
potential hazards; (c) identify hazards which must be controlled; (d) recommend controls, critical
limits, and procedures for monitoring and verification; (e) recommend appropriate corrective actions
when a deviation occurs; (f) recommend research related to the HACCP plan if important information
is not known; and (g) validate the HACCP plan.
Describe the food and its distribution
The HACCP team first describes the food. This consists of a general description of the food,
ingredients, and processing methods. The method of distribution should be described along with
information on whether the food is to be distributed frozen, refrigerated, or at ambient temperature.
Describe the intended use and consumers of the food
Describe the normal expected use of the food. The intended consumers may be the general
public or a particular segment of the population (e.g., infants, immunocompromised individuals, the
elderly, etc.). Develop a flow diagram which describes the process. The purpose of a flow diagram is
to provide a clear, simple outline of the steps involved in the process. The scope of the flow diagram
must cover all the steps in the process which are directly under the control of the establishment. In
addition, the flow diagram can include steps in the food chain which are before and after the
processing that occurs in the establishment.
Verify the flow diagram
The HACCP team should perform an on-site review of the operation to verify the accuracy and
completeness of the flow diagram. Modifications should be made to the flow diagram as necessary
and documented. After these five preliminary tasks have been completed, the seven principles of
HACCP can be initiated.
 Conduct a hazard analysis
Plan to determine the food safety hazards and identify the preventive measures the plan can
apply to control these hazards. A food safety hazard is any biological, chemical, or physical
property that may cause a food to be unsafe for human consumption.
 Identify critical control points
A critical control point (CCP) is a point, step, or procedure in a food manufacturing process at
which control can be applied and, as a result, a food safety hazard can be prevented,
eliminated, or reduced to an acceptable level. •
 Establish critical limits for each critical control point
A critical limit is the maximum or minimum value to which a physical, biological, or chemical
hazard must-be controlled at a critical control point to prevent, eliminate, or reduce that hazard
to an acceptable level Establish critical control point monitoring requirements Monitoring
activities are necessary to ensure that the process is under control at each critical control
point. In the United States, the FSIS requires that each monitoring procedure and its frequency
be listed in the HACCP plan

 Establish corrective actions

These are actions to be taken when monitoring indicates a deviation from an established
critical limit. The final rule requires a plant's HACCP plan to identify the corrective actions to be
taken if a critical limit is not met. Corrective actions are intended to ensure that no product is
injurious to health or otherwise adulterated as a result if the deviation enters commerce.
 Establish procedures for ensuring the HACCP system is working as intended
Validation ensures that the plants do what they were designed to do; that is, they are
successful in ensuring the production of a safe prodụct . Plants will be required to validate their
own HACCP plans Verification ensures the HACCP plan is adequate , that is working as
intended. Verification procedures may include such activities as review of HACCP plans, CCP
records, critical limits and microbial sampling and analysis.
 Establish record keeping procedures
The HACCP regulation requires that all plants maintain certain documents , including its
hazard analysis and written HACCP plan, and records documenting the monitoring of critical
control points, critical limits, verification activities, and the handling of processing deviations.
 Implementation involves monitoring, verifying, and validating of the daily work that is compliant
with regulatory requirements in all stages all the time.

CHAPTER 10
FOOD SAFETY PLAN
LEARNING OUTCOMES:
 Designing an FSP or a Food Safety Plan.
 Listing the elements of a Food Safety Plan.
 Enumerating the different stages in the Food Safety Plan.
 Understanding the preventive measures and control limits in the development of a Food Safety
Plan.
 Assessing the basic requirements in the development of a Food Safety Plan. ensure

Recently, a number of foodborne illnesses which occurred worldwide have aroused the
concern and anxiety of the public about food safety. Most of these foodborne illnesses are caused by
mishandling or improper preparation/ storage of food by food handlers. In order to food safety and
prevent food poisoning, all food businesses including food service organizations should comply with
the existing food regulations as well as prepare their own Food Safety Plan (FSP) based on the
principles of Hazard Analysis and Critical Control Point (HACCP) system.

HACCP adopts a proactive approach to anticipate the occurrence of potential problems during
the food production process and to implement measures designed to prevent the occurrence of these
problems.

HACCP system has been adopted worldwide by many food manufacturing companies.
However, a "classical" HACCP system is generally considered not feasible in the food service
organizations due to the multiplicity of food products, lack of standardised methods, lack of
systematic production planning as well as lack of expertise to develop the system. This document
contains an FSP based on the principles of HACCP in order to assist managers of food service
organizations to tackle the above problems and ensure food safety, including:
 an outline of the stages involved in developing an FSP;
 a list of potential problems that may occur during food production in catering operation
 a list of control measures that can be applied generally to most catering operations and
advices on when and how these control measures can be applied.

What is a Food Safety Plan?

An FSP is designed to identify and prevent possible food safety problems (hazards) in order to
enhance food safety. The problems may relate to the purchasing, receiving, storing preparing,
cooking, packaging, transporting or displaying of food.
There are six elements in an FSP.
 List food safety problems (hazards) at each step of the food processing.
 Identify preventive measures and their control limits.
 Establish monitoring procedures.
 Establish corrective actions.
 Keep records.
 Check and review.

Appropriate implementation of the above elements, together with the application of basic practices
(e.g. cleaning and sanitation, personal hygiene, pest control, waste disposal and staff training) will
certainly prevent food safety problems during the food production.

Implementation a Food Safety Plan

Stage 1 Planning
Preliminary planning and preparation will be essential before developing your FSP. A
coordinator for developing an FSP should be appointed and adequate authorities and resources
should also be provided. The coordinator must have basic knowledge of food safety and must be
familiar with the properties of food as well as its processing procedures.

Staff should be made aware of the changes and benefits that will result from the introduction of
the FSP. The FSP will only work if each staff member knows his/her role in the plan, and is committed
to making it work. To reduce the anxiety of staff, the FSP should be introduced in phases over a
period of time. For example, the FSP could be introduced initially for just the first step of the catering
operation (i.e. purchase of raw materials), making sure that the first step is working properly before
moving onto the next step.

Stage 2 Draw a flow diagram

A flow diagram should be drawn showing each step in the operation, from purchase of raw
materials to serving food to consumers. The flow diagram shown here is a generic example for a
catering operation which should be tailored to each individual operation. Each of the steps of the
operation can be considered a control point to prevent food safety problems.
Step 2 Identify preventive measures and their control limits
 List the measures and the control limits that can be used to control the identified problems (i.e.
those identified at step 1) at each step of the catering operation. A control limit is a value or
measurement (such as temperature or acidity) that must be met to ensure safety of the product.
Table 10.1 Preventive Measures and Control limits
Examples of preventive measures and their control limits are:
Preventive measures Control limits
Using reputable suppliers Products bought from approved / licensed
and reputable suppliers.
Adequate freezing or chilling Frozen / chilled foods should be stored at
-18°C 14°C or below.
Using proper ways to thaw Frozen foods Frozen food should be thawed under/in
? refrigeration at 4°C or below

? cool running water in waterproof

package
? a microwave oven
Cooking thoroughly During cooking the core food temperature
should reach 75°C or above for at least
30 seconds
Proper cooling Cooked foods should be cooled from
60°C to 20°C in two hours and then to
4°C or below in the next four hours

Step 3 Establish monitoring procedures

The monitoring of control limits will ensure that any loss of control (i.e. deviation from control
limits) can be identified so that corrective actions can be taken before the product becomes unsafe.
The methods used should be kept as simple as possible.
Examples of monitoring procedures include:
 Cooking temperature and time measurements
 Visual observation of "use by" date and stock rotation
 Visual observation of cleanliness of equipment and work surface
 Visual inspection of incoming food ingredients Simple and clear work instructions for the
control and monitoring procedures that should be developed for staff to refer to:
 What is to be checked? (e.g. the cooking temperature)
 How is it checked? (e.g. use thermometer to measure temperature)
 When is it checked? (e.g. measure once every half hour)
 Who does the check? (e.g. chef assistants)
Step 4 Establish corrective actions
If monitoring procedures reveal loss of control, corrective actions must be taken immediately.
Examples of corrective actions:
 Reheat the food until its core temperature reaches 75°C or above for at least 30 seconds if the
cooking temperature is inadequate.
 Adjust or repair the chiller if its temperature is higher than 40C.
  Clean the equipment again if it is dirty.

Step 5 Keep records

Maintenance of monitoring records (e.g. temperature records of the freezer) helps evaluate
whether preventive measures are adequate and efficient. Step 6 Check and review

In order to ensure that your FSP works properly, you should perform a systematic check
periodically (e.g. once a week). The checklist may help you determine areas in your operation
requiring attention and improvement . In addition, you should also review your FSP at least once a
year because your operation or products may change.

Examples of application of Food Safety Plan

Following are examples of possible problems and their controls for each step in the food service
operation:
Basic requirements for a Food Safety Plan
An FSP should also include some basic activities (eg. cleaning and sanitation, personal
hygiene, pest control, waste disposal and staff training) so that potential problems arising from the
food production process will be prevented more effectively. Listed below are the examples of these
activities.
A. Cleaning and sanitation
Food preparation areas, facilities, equipment and all food contact surfaces should always be
kept clean because food residues and dirt may contaminate food resulting in food poisoning. A
cleaning programme should therefore be developed to ensure that cleaning and sanitising be carried
out in a systematic, regular and effective manner.
The steps for cleaning and sanitising of utensils are as follows:
 Remove debris by wiping, scraping.
 Rinse with hot water.
 Clean with detergents.
 Rinse with water.
 Sanitize with hot water or chemical sanitisers (instructions for use and safety precautions on
the labels should always be followed when using chemical sanitisers).
 Air dry.

In order to ensure that cleaning and sanitation is carried out effectively in your premises, you
should develop a well-planned cleaning and sanitation programme and maintain relevant records for
evaluation. A well-planned cleaning and sanitation programme should include the following elements:
 areas, utensils and equipment to be cleaned
 frequency of cleaning required for each item
 cleaning procedure specified for each item
 equipment and methods to be used
 chemicals or systems to be used
 the staff responsible for each task
B. Personal hygiene

Good personal hygiene is essential to ensure food safety. Food poisoning bacteria may be
present on the skin and in the nose of healthy people. All food bandiers must therefore maintain a
high standard of personal hygiene and cleanliness in order to avoid transferring food poisoning micro-
organisms to food. The following points need to be considered by all food handlers:

Handwashing
Hands must be washed:
 Before working
 Before preparing food
 After going to toilets
 After handling raw foods
 After licking fingers, coughing, sneezing, eating, drinking or smoking
 After touching cars, nose, hair, mouth, or other bare body parts
 After touching pimples or sores
 After handling waste
 After carrying out cleaning duties
 After changing soiled clothes
 After handling animals
 After any other unhygienic practices

How to wash your hands:

 Wet hands with warm running water.
 Apply soap
 Rub hands for 20 seconds (If necessary, use a nail brush to clean nails. However, the brush
must be kept clean and sanitary).
 Rinse hands thoroughly.
 Dry hands with a paper towel (the paper towel can then be used to turn off the tap).
 Turn off the tap with the paper towel.

Hand care
 Keep fingernails short and clean.
 Cover all wounds or cuts on hands or arms completely with bright-coloured waterproof wound
strip.
 Wear disposable gloves if there are wounds on hands. Change both gloves and wound strip
regularly

Clothing and appearance

 Uniforms and aprons (or clothes) should be clean at the beginning of a work shift.
 Wear a hair restraint (hat or hairnet)
 Avoid wearing jewellery while handling and preparing food:
 Avoid using strong perfumes/after-shaves.
 Do not wear uniforms / aprons outside the food preparation area.
Personal hygiene practices while handling food
 Avoid touching nose, mouth, hair and skin during food preparation.
 Do not smoke in food premises.
 Do not cough or sneeze directly onto food.
 Wash hands after coughing or sneezing Wash hands after blowing nose.
 Use disposable tissues to wipe hands.
Infection
Food handlers should be free from any illnesses such as gastroenteritis or flu
 Cease working and report to the manager when feeling ill.

C. Pest control

Pests may contaminate food and cause foodborne illness. A pest control programme should
be developed to eliminate pests and prevent posts from infesting your food premises. An effective
pest control programme should be able to prevent access, deny harborage and eradicate any pests
present.

 Keep doors to the outside closed at all times.

 Fit windows open directly into food preparation areas with screens (with apertures of two
mm2or less) to keep insects out.
 Cover ventilation ducts and floor drains.

Preventive measures
 Store food and supplies properly.
 Cover them properly.
 Store them at least 30cm/twelve inches off the floor and 15cm/six inches away from walls.
 Store them at low humidity (50 per cent or less).
 Apply first-in-first-out system.
 Remove cartons, newspapers, etc. that may attract and harbour pests.
 Store and remove garbage properly and regularly.
 Keep refuse bins covered. Keep garbage in scaled plastic bags and inside tightly covered
refuse bins.
 Clean up spillages of food immediately
 Keep toilets clean and hygienic.

Inspection

 Inspect both outside and inside of premises frequently (e.g. weekly) for signs of pests.
 Check incoming food and supplies for signs of pests (e.g. any pest is harboured inside the
packaging of food and supplies).

Elimination
 Use chemical, physical or biological means (e.g, rodent traps) where there are signs of pests.
  Use a zapper or insecticutor to capture and kill flying insects. Ensure zappers are not above or
within three metres of a food preparation or storage area.
 Avoid spraying insecticide over food preparation surfaces.
 Hire a professional pest control company when necessary.
 Seal all gaps around fittings or in walls or floors.
D. Waste disposal
Waste can be regarded as any item of foods, ingredients, packaging materials, etc. which is
not suitable for further use and intended to be disposed of. Waste should be controlled carefully since
it presents a risk of contamination of food
 Waste disposal bins should be placed near the working area of food preparation rooms and
positioned conveniently to operating staff
 Waste disposal bins should be clearly distinguishable from other storage bins.
 A defined area should be allocated for the storage of waste pending disposal
 When food waste is removed from food preparation area pending disposal, it must be placed in
a tightly covered waste storage bin.
 Plastic liners should be used in waste disposal and storage bins.
 Waste disposal and storage bins should be emptied when full or on a regular basis.
 Waste disposal bins should be cleaned and sanitised daily and placed upside down and off the
floor to drain overnight.

E. Staff training

Training offers food handlers a better understanding of how food can become contaminated,
and how foodborne illnesses can be avoided through proper food handling procedures. Each food
business must decide what training their food handlers need by identifying the areas of their work
most likely to affect food hygiene and safety.
Examples of basic knowledge of food safety:
 Main factors contributing to outbreaks of foodborne illnesses
 Temperature control of potential hazardous foods
 Proper ways of using equipment (e.g. the skill of using thermometer, knowledge of handling
cooking and storage equipment)

Examples of basic knowledge of food hygiene:

 Skills and significance of maintaining good personal hygiene practices
 Knowledge and skills of cleaning and sanitising
 Pest control
 It is a good practice for a business to identify the training needs of each staff member.
 It is also a good practice to keep training records of every staff member.
 Training needs should be reviewed on a regular basis and should be assessed against the
role and responsibilities, existing skills, experience and previous training of the staff

F. Handling customer complaints

Customer complaints should be handled carefully because they help reflect possible problems
that may be overlooked by the management during food production. Depending upon the results of
investigation, appropriate amendments to the FSP should be made where necessary.
 Establish complaint handling procedures.
 Document all costumer complaints.
 Record details including the date, customer details, reasons for complaining and action taken.