HACCP and Food Recall Essentials for
School Nutrition Professionals
Cindy Rice, RS, MSPH
October 19, 2016
Nuts and Bolts Workshop DESE
Framingham State College
Insects flying
Falling dirt
Food mixed with bare hand, cuts
Foods in TDZ for 5 hours
Worker did not wash hands after restroom and then put fruit in
bowl
Food Safety Essentials
Learning objectives
• Understand the main hazards to food
• Identify TCS foods and their characteristics
• Know the major allergens and control measures
• Foodborne Illness
A disease that is carried or transmitted
to people by food
• Outbreak
An incident in which 2 or more people experience
the same illness after eating the same food
Foodborne Illness
High Risk Populations
People with weakened immune systems
Babies & Children under 4
Elder Adults Chronic disease or ill individuals
High risk individuals
AVOID:
Raw Sprouts
Soft cheeses
Cold cuts/Deli Meats
Rare meats
Raw seafood
(Use Pasteurized eggs)
TCS Time and Temperature Control for Safety foods
(formerly Potentially Hazardous Foods)
Bacteria will grow easily:
• High in protein or carbohydrates
• Moist
• Neutral or only slightly acidic
TCS foods
Which type of food would be the most likely to cause a foodborne illness? A. Tomato juice B. Cooked rice C. Whole wheat flour D. Dry powdered milk
Pop Quiz
All of the following conditions typically support the growth of microorganisms EXCEPT: A. moisture B. a protein or carbohydrate food source C. high acidity D. time
Pop Quiz
Personal Hygiene
• Wash hands properly
• Stay clean
• Don’t work while sick
• Don’t eat, drink or smoke around food
Time and Temperature Abuse
Major cause of foodborne illness outbreaks
Bacteria grow to dangerous levels
in TDZ (Temperature Danger Zone) 41° F – 140° F 2 hour maximum for Schools Discard
140 ° F
41° F
Time and Temperature Controls
Minimize time at 41° F – 140° F
Keep TCS foods under 2 hours total
Receive & store TCS foods quickly
Refrigerate TCS foods at proper temperatures, 41° F or lower
Cook foods to safe internal temperatures
Hold foods at proper temperatures
Cool, thaw, reheat foods properly
Cross-Contamination
• Wash hands after handling raw foods
• Don’t allow raw foods to touch or drip onto cooked or ready-to-eat foods
• Clean and sanitize food contact surfaces, cloths
• Eggs • Dairy • Wheat • Soy (tofu) • Tree nuts • Peanuts • Fish • Shellfish Protein in the food is what causes the allergic reaction Gluten, Lactose Intolerances- sensitivities
Food Allergens – The Big 8
Preventing Allergic Reactions
Prevent cross-contact
• Avoid use of offending ingredients
• Know ingredients, read labels
• Use clean equipment, gloves
• Separate fryers
and cooking oils
Use Clean Equipment
Wash, rinse (and sanitize) all surfaces
• pots, dishes
• utensils, tables
• cutting boards
• wiping cloths
Foodborne microorganisms grow well at temperatures between A. 75° F and 165° F B. 32° F and 79° F C. 38° F and 155° F D. 41° F and 135° F .
Pop Quiz
Which of the following is not a common food allergen? A. Tofu B. Dairy products C. Peanuts D. Strawberries
Pop Quiz
HACCP
• Hazard Analysis Critical Control Point
• A written plan, an organized way of how foods
are prepared in an operation
Learning objectives
• Identify the 7 HACCP principles
• Know the methods for identifying hazards in foods in a HACCP plan
• Identify Critical Control Points, monitoring and recordkeeping procedures
Why HACCP?
So we can...
• Prevent hazards
• Eliminate hazards
• Reduce risks to safe levels
Hazards = anything that may cause illness
7 HACCP Principles
Principle One Conduct a Hazard Analysis
Principle Two Determine the CCPs
Principle Three Establish Critical Limits
Principle Four Establish Monitoring Procedures
Principle Five Take Corrective Action
Principle Six Verify that the system works
Principle Seven Record keeping
1. Conduct Hazard Analysis
• Identify potentially hazardous foods from your menu
• Determine which are significant and must be addressed in HACCP plan
2. Critical Control Points (CCP)
LAST step where it is ESSENTIAL that you
intervene to make that food safe to eat (prevent, control, or eliminate hazards in food before service)
CCP
3. Establish Critical Limits
• “Magic” number that the CCP must meet
eg, pH value, temperature, time limit
• Prevent, eliminate or reduce risk to safe level
HACCP plan recipe
CCP
Receive fresh < 41°F; Inspect quality of package
Refrigerate < 41°F; Store on lower shelf, no contamination
Place into roasting pan, sprinkle with herbs Clean & Sanitize surrounding area
Cook for 3 hours, to internal temp 165°F for 15 secs
4. Monitoring
• Monitoring (taking a measurement) lets you know
if critical limits are being met
• Be specific about
Who- What- When-Where- How you will monitor
• Equipment and tools needed
HACCP plan recipe
CCP
Receive fresh < 41°F; Inspect quality of package
Refrigerate < 41°F; Store on lower shelf, no contamination
Place into roasting pan, sprinkle with herbs Clean & Sanitize surrounding area
Cook to internal temp 165°F Measure thigh and breast with a
sanitized, bimetallic thermometer
Slice turkey, put into clean hotel pan. Hold HOT at 135°F. Serve with clean sanitized tongs.
Empty into smaller containers. Cool in ice bath to 70° F within 2 hrs, Cover, put in refrigerator on top shelf.
5. Take Corrective Action
Predetermined steps to take when food does
not meet a critical limit
(if something goes wrong)
6. Verification
Manager determines if your HACCP system is working
according to the plan, and if:
• CCP’s and critical limits are appropriate
• Corrective actions are adequate
• Employees are following procedures
7. Recordkeeping
Proper records allow you to document you are continuously preparing and serving safe food
7. Recordkeeping
• Temperature logs,/sanitizing logs
• Thermometer calibration checks
• Corrective action charts, receiving temps
Records can protect you.
Standard Operating Procedures
Must be in place
for HACCP plan to
work properly
Personal hygiene Cleaning & sanitizing
Reputable suppliers Proper equipment Staff Procedures
The temperature of a roast is checked to see if it has met its critical limit of 145° F. This is an example of which HACCP principle? A. Verification B. Monitoring C. Record-keeping D. Hazard Analysis
Pop Quiz
The temperature of a pot of beef stew is checked during holding. The stew has not met the critical limit of 140° F, and is discarded according to school policy. This is an example of which HACCP principle? A. Monitoring B. Corrective action C. Hazard analysis D. Verification
Pop Quiz
Which of the following Standard Operating Procedures should be in place before you begin developing your HACCP system? A. Personal hygiene program B. Incentive program C. Workplace accident prevention program D. None of the above .
Pop Quiz
48
• Know how to characterize menu items into Process Groups
• Understand importance of Standard Operating Procedures in controlling hazards
• Identify Critical Control Points for menu items
Learning objectives
49
Procedures that address basic operational and sanitation conditions in an operations
1. Develop Prerequisite Programs
Prerequisite Programs - Purpose
Protect your products from contamination
Control bacterial growth
Proper procedures
Clean and sanitized equipment
Personal hygiene and health of workers • Approved suppliers, water
51
• Who?
• What?
• When?
Standard Operating Procedures SOPs Written specifically for your school
• Where?
• How?
• Why?
Bacteria
Viruses
Poor personal hygiene
Physical objects
Chemical contamination
52
2. Identify Hazards in foods
Diagram that shows the step-by-step progression or “flow” of food through a food preparation process, in sequential order
53
3. Make a Flow Chart for all foods
Use the recipe and/or preparation procedures to lay out food flow into major operational steps...
54
55
Group menu items into 1 of 3 food preparation processes •Process 1 •Process 2 •Process 3
FLOW CHARTS help to group items that have similar processes
Flow of food
Receiving Store Prepare Hold Serve Examples
Sandwiches w/ RTE Fillings Canned Tuna Canned Chicken Deli Meat
Salads Fresh fruits
58
Process 1: Food Preparation with No Cook Step
NO complete trip through Danger Zone
Flow of food
Receive Store Prepare Cook Hold Serve
Examples (all for immediate service)
Hamburgers
Roast turkey
Stir fry dishes
59
Process 2: Preparation for Same Day Service
1 complete trip through Danger Zone
Flow of Food
Receive Store Prepare Cook Cool Reheat Serve
Examples
Hot Catered Meal (prepared ahead)
Soup prepared in advance for next day service
Chicken salad made from scratch
Process 3: Complex Food Preparation
2 or more complete trips through Danger Zone
Fried Chicken Recipe
• The chicken is received frozen and stored in the walk-in cooler until thawed.
• Chicken is rinsed with water, dipped in buttermilk and flour.
61
What’s the Process Group?
• Chicken is deep fried for 15 minutes at 400o F.
• Chicken is placed to metal sheet pan and placed under a heat lamp/steam table until served.
62
Fried Chicken
64
FRIED CHICKEN How many times through Danger Zone?
RECEIVE STORE THAWING
COOK HOT HOLD SERVE
Process 2: Preparation for Same Day Service
TUNA SALAD How many steps through Danger Zone?
RECEIVE STORE ASSEMBLE
STORE SERVE
Process 1: Food Preparation with NO Cook Step What are CCP(s)? Critical limits?
CCP
0
Chicken salad (made in-house from scratch) How many steps through Danger Zone?
RECEIVE STORE COOKING
COOLING SERVE
Process 3: Complex Food Preparation
What are CCP(s)? Critical limits? Other way to make it a different Process?
CCP
CCP
PREPARE
67
PROCESS Approach
•Critical control points are identified for Groups of menu items (Process 1, Process 2, Process 3 items) •Critical limits may be different within that Group (Meats and poultry in same Process group but have different cooking temperatures) •Critical limits for different foods are identified in SOP for that Procedure (e.g., Cooking)
Chicken casserole, Taco filling
How many steps through Danger Zone?
RECEIVE STORE COOKING
COOLING REHEATING SERVE
Process 3: Complex Food Preparation
What are CCP(s)? Critical limits? SOP’S ?
CCP CCP
CCP
PROCESS HACCP
Which is the first step in grouping menu items into the correct Process Group?
A. Identify hazards of the ingredients
B. Create a Flow chart for each recipe
C. Identify control measures
PROCESS HACCP
Which Process group travels through the Temperature Danger Zone 2 or more times?
A. Process 1
B. Process 2
C. Process 3
PROCESS HACCP
Every Critical Control Point requires a
A. Certified HACCP Manager supervision
B. Validated cooking temperature
C. Monitoring and Recordkeeping activity
.
Kiwis ...Italy
Hazelnuts ...Asia
Strawberries ...California
Apricots ...Turkey
Raspberries ...Canada
Cocoa beans ... Amazon
Cream ...Ireland
Learning Objectives
• Define a food recall
• List three reasons why a food recall may be initiated
• How is a food recall initiated
• What are the 3 classes of recalls
Agencies Responsible for
Purchasing USDA Foods
• USDA Agricultural Marketing Service (AMS)
• USDA Farm Service Agency (FSA)
• US Department of Defense (DOD)
Food Contaminations
During production or distribution… • Accidentally (food safety issue) • Intentionally by sabotage, fraud (food defense issue) • Discovered by Regulatory or Manufacturer Food Recall Goals: Remove product from market Prevent sale or consumption
• Undeclared allergen
• Detection of hazard or disease-causing organism
• Misbranded or mislabeled product
Common causes
3 Classes of Recalls
Class 1 Reasonably likely to cause illness
E.coli (produce) Salmonella (peanut butter) Listeria (RTE)
Class 2 Remote possibility of illness
Yellow dye # 5
Class 3 Unlikely adverse effects Ingredient label not in English Defective packaging
Flow of the Recall Notice
RECALL NOTICE issued by manufacturer, supplier,
government, other)
Restaurants, Schools receives notice
On-site managers notified
Response actions by
staff
Product removal,
return
Customers notified
Product return,
disposal
Works with supplier for
proper actions
Regulatory agency
receives notice
Coordinates with industry
response
Product identification
Company Name
Brand Name
Case Markings
Establishment number (for meat, poultry, or eggs)
Product Markings
Note: UPC Code is not be adequate
Pizza that has a label that has not been positioned correctly on the box is an example of a __________ food recall.
A. Class I
B. Class II
C. Class III
D. Unidentified Class
Which of the following is not typically used to identify foods in a food recall event?
A. Lot number, UPC code, Batch #
B. Packaging characteristics
C. Recall notice
D. Food temperatures
A common cause of food recall includes
A. Undeclared allergens
B. Metal fragments in food
C. Lab identified microorganism
D. All of the above
Learning Objectives
• Locate website to sign up to receive food safety recalls
• Identify responsibilities during a food recall
• Evaluate standard operating procedures for responding to food recall
USDA Food Recall Flow Chart
AMS or FSA Purchase & Product Information
RAS/ WBSCM
USDA FNS NO
NPA Processors
Customers
SDA(Food Safety
Contact) SENS
RAs In-state
Processors Other
Entities
State Contracted Distributors
State Agency Responsibilities
• Notify Schools/ Recipient Agencies (RA) about
recalled items
• Implement standard operating procedures
• Provide disposal instructions to RAs
• Contact Processors, Distributors… instruct to ISOLATE, TRACK product in inventory
• Recall reimbursement paperwork
State-owned or Contracted
Warehouses
• Identify USDA Foods
• Document to whom USDA Foods were distributed
• Identify who received USDA Foods
• Submit inventory data to State or owner
• Conduct annual review and document compliance
RAs . Schools Responsibilities
• Have written recall procedures in place
• Assign food safety coordinator, with contact information
• Notify all sites, Schools about recalled items
• Follow instructions for Isolation or Disposal
• Avoid eating/serving recalled products, even if cooked
Product Isolation
• Segregate products until returned or declared safe
• Label clearly: “Do Not Use”
• Follow manufacturer’s instructions, FNS, USDA directives
• Alert Receiving areas
IF NECESSARY…
• Discard in a manner that prevents use or eating
• Follow guidelines by USDA, FNS, manufacturers
• Document discarded products in recordkeeping system
Disposal
Product Destruction Form
Commodity # Cases Destroyed
Contract # Destruction Method
Witnesses Print Name Signature Date Destruction Observed
Witness 1
Witness 2
Name of State Agency __________________________________________ Name of Recipient Agency_______________________________________________________
School District Contact Information:
Before receiving a recall notice, RAs should
A. Implement recall procedures
B. Identify hazards in foods
C. Develop a food recall plan
D. Communicate with FSIS about commodities
An initial activity during a food recall is most likely to:
A. Identify hazards for Process 3 foods
B. Notify all schools about the recall
C. Discard all products immediately
D. Send a press release to student families
Recalls Exercise
Whose Responsibility is it?
F= Federal Agency
S= State Agency
R= Recipient Agency
P= Processor
D= Distributor
Learning objectives
• Understand methods for tracking products
• Training staff
• Conducting a mock recall
RA Tracking products
Inventory assessment in 48 hours or less Identify locations of affected product and quantity:
• Served • Remaining in-stock at schools, warehouses, distributors • Distributed to other programs • Redirected for further processing
Submit information to SDA
Critical Tracking Events
Points when product:
• Is received
• Used in production
• Is served, stored or discarded
• Shipped to another location
• Used as a leftover o Reheated
o Served or Discarded
Overall Goal
Prevent sale or consumption of Recalled foods
• Communicate with staff, others about health risks
• Work cooperatively with State/Food Regulatory agencies
• Coordinated messages to schools, public
• Document your actions
• Train staff in advance of recall event
• Demonstrate methods for isolation, destruction
• Completing forms, recordkeeping
• Evaluate gaps in your system and re-train as necessary
• Conduct a mock recall
Training staff
1. Identify date and time of mock recall of produce item
2. Unannounced “TEST”
3. Have produce tracking information from vendor ready
4. Communicate produce recall to all necessary personnel
5. Provide identification information to all parties
Lot/batch #, product codes, dates, photos, etc
1. Assess affected products at each school
2. Calculate total product ( % ) accounted for at each
location (Amount in inventory, used, distributed)
3. Calculate total time to conduct the Mock recall activities
1. Identify gaps in recalls system
2. Corrective actions, revise SOPs if necessary
3. Train staff
4. Conduct another mock recall, different product, using
improved procedures, training
Conducting a Mock Recall in a School Nutrition Operation http://www.nfsmi.org/documentlibraryfiles/PDF/20130726045907.pdf
Handling complaints
• Gather information regarding complaint, product, symptoms, location, etc
• Communication
• Documentation
• Use Standard Operating Procedures for recordkeeping
Learning objectives
• List four types of records that must be kept regarding USDA Foods
• Procedures for Reimbursements
• Handling complaints
Inventory Management System
Shows
• What food is in inventory
• When food was received
• Where food is stored
• When and where food was distributed
Reimbursement for Costs
USDA Foods Costs are limited to:
o Storage
o Transportation
o Processing
o Distribution
General Steps in Reimbursement
RAs submit original receipts & request for
reimbursement
SDA combines all requests for State &
reports data in WBSCM
SDA submits public voucher, FSA-21, &
supportive documents
USDA FNS Regional Office reviews SDA’s
claim & documentation
USDA FNS National Office reviews SDA’s
claim & documentation
USDA AMS reviews and approves
expenses
USDA AMS submits public voucher for
payment
SDA reimburses RAs (SFAs, processors,
distributors)
USDA FNS NO coordinates product replacement or
entitlement reimbursement with SDA