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HACCP is an acronym for the Hazard Pillsbury Company, the National Analysis and Critical Control Point Hazard Analysis and Aeronautic and Space Agency system. HACCP is a preventative (NASA), the Natick Laboratories of system that is used in the food industry Critical Control the U.S. Army, and the U.S. Air Force to help ensure food safety. The basis for Space Laboratory Project Group worked HACCP is to identify potential hazards Points together on a project in food produc- associated with food production and tion for the NASA space program. The preparation, and to develop mecha- (HACCP) pathway of HACCP started in 1959 nisms to eliminate or control these when Pillsbury was asked to produce a hazards. HACCP can be applied to all for Foodservice food that could be used under zero areas of food production, from the farm gravity conditions in space capsules. In to the homes of consumers. HACCP is and Food Retail 1959, they began the project knowing important to all segments of the food Operations basically nothing about how foods industry. might react under zero gravity condi- tions. The most difficult and perhaps During the past twenty years, most Dr. Richard Linton, most important aspect of the project HACCP programs have been dedicated Extension Specialist was to develop a system to assure that to food processing plants which are in Department of Food Science food products would not be contami- the “middle” of the food production nated with biological, chemical, or chain. More recently, the food industry physical hazards. Such hazards might has realized the importance of establish- Dr. Barbara Almonza, result in an aborted or catastrophic ing HACCP principles for the end of mission. the food production chain: retail food Associate Professor and foodservice operations. Department of With these problems in mind, the Restaurant, Hotel, Institutional, and research groups concluded it was The use of HACCP can complement Tourism and Management necessary to develop a preventive food quality control programs. When safety system that would reduce the measures are taken to assure food safety, Purdue University likelihood of biological, chemical, and this generally results with better food physical hazards. In doing so, control quality. HACCP is not a stand-alone could be achieved over all aspects of system! Effective cleaning and This publication was reviewed by the food production including raw material, sanitizing programs and maintaining following outside reviewers: processing, environmental conditions, the health and cleanliness of the food Dr. Joseph Eifert, Ph.D. personnel, storage, distribution, and handler are also important for assuring a Manager of Microbiology, Nestle transport. This approach, referred to as safe, high-quality food. These programs USA, Inc HACCP, worked well for the NASA are typically not part of HACCP Dr. Jeff Rhodehamel, Ph.D. space program, and was quickly adapted programs because they are difficult to Microbiologist by the food industry. monitor, and safe limits have not been U.S. Food and Drug Administration clearly established. Dr. Cameron Hackney, Ph.D. A Systematic Study Professor of HACCP involves a systematic study of History of HACCP Virginia Polytechnic Institute and the ingredients, the food product, the The concept of HACCP was initiated State University conditions of processing, handling, by the Pillsbury Company. The

Department of Food Science • Purdue Cooperative Extension Service storage, packaging, distribution, and consumer use. The complete analysis Figure 2. Common hazards in foodservice and food retail operations. allows for the identification of the Biological: “sensitive” areas in the process flow Pathogenic bacteria (i.e spp., Staphylococcus aureus) which might contribute to a hazard. Viruses (i.e. ) From this information, “Critical Parasites (i.e. Trichinella spiralis) Control Points” (CCP’s) can be Rodents and insects (can carry bacteria, viruses, parasites) determined. Areas identified as CCP’s Chemical: are monitored and limits are deter- Naturally occurring (i.e. seafood toxins) mined to control potential hazards. Added chemicals (i.e. cleaning agents, pesticides) When properly applied, HACCP can be used to control any area or point in Physical: the food system which could contribute Inherent to food (i.e. bone particles) to a hazardous situation whether it be Non-inherent to food (i.e. glass, stone, wood) contaminants, disease-causing microor- ganisms, physical objects, chemicals, raw materials, an unsafe process, CCP’s to control biological hazards in package labeling, or storage conditions. Determine CCP’s This step identifies critical areas or foodservice and food retail operations There are seven principles which are points of the flow of a food product that are usually time and temperature related used to develop and implement a are required to control the identified since they can be easily monitored. HACCP program (Figure 1). hazards. For an area to be considered a Time and temperature are also the most CCP, loss of control would mean the important factors permitting growth of likelihood of an unacceptable health bacteria. Occasionally, a measurement Figure 1. Seven principles of hazard. In HACCP programs, some- in pH (acidity of a food) may also be HACCP. times “control points” (CP’s) will also used as a critical limit. Although 1) Analyze hazards be identified. A CCP is different from a important, limits for chemical and physical hazards are used less often in 2) Determine CCP’s CP (Figure 3). A CCP indicates a high food safety risk (likely to occur) and a HACCP plans for foodservice and food 3) Establish critical limits for CCP’s CP indicates a low food safety risk (not retail. Chemical and physical hazard 4) Monitor CCP’s likely to occur). Food safety relies on levels are usually more easily monitored 5) Take corrective action identification and control of CCP’s, and controlled prior to receipt at a foodservice and/or food retail establish- 6) Do record keeping while, CP’s may be used for quality specifications. ment. For chemical hazards, it will be 7) Verify that the system is working important to ensure that chemicals (cleaning agents) are separated from Figure 3. CCP or CP ? foods. A visual inspection can be used Hazard Analysis for physical hazards. In the first step of HACCP, it is If control is lost, is it LIKELY that a health Time and temperature limits can be set important to identify potential hazards risk will occur? for various areas of retail food produc- that might be associated with growing, If the answer is YES, this is considered a tion. They include receiving, cold harvesting, raw materials and ingredi- CCP. storage, thawing, cooking, cooling, ents for processing, manufacturing, If the answer is NO, this is considered a CP. reheating, hot-holding, and cold- distribution, marketing, preparation, holding of foods. Some suggested and consumption of the food. critical limits are included in Figure 4. The purpose of hazard analysis is to identify all potential hazards (biologi- Establish Critical Limits for Monitoring CCP’s cal, chemical, and physical) that may CCP’s Monitoring CCP’s includes the be associated with the flow of a given This step establishes upper and/or lower recording of data (temperature, time) food. Some potential hazards of concern limits for each CCP. CCP’s are set for for limits which have been set for each in foodservice and retail foods are foods that can naturally carry and/or CCP in the HACCP plan. Data identified in Figure 2. The types of support the growth of a foodborne collection is important to assure that hazards depend on the type(s) of foods hazard. These types of foods are called CCP limits are being met. The and preparation practice(s) involved. potentially hazardous foods. Limits for procedures and frequency for monitor-

2 ing CCP’s will differ depending on the type of food(s) and the preparation Figure 4. Temperature/time critical limits for retail food preparation. practices used. Receiving: Internal temperature should be <41°F for all potentially hazardous foods. Corrective Action Cold Storage: Internal temperature should be maintained at <41°F for all potentially If monitoring shows that a limit for a hazardous foods. CCP has been exceeded, corrective Thawing: Refrigerator thawing at <41°F is suggested. Microwave thawed foods action procedures must be in place to must be cooked immediately after thawing. Cool water thawing must be done at <70°F for assure the safety of the food. Corrective <2 hours from a continuously running potable water supply. Thawing at room temperature action procedures may range from is not acceptable. discarding the product to simply Preparation of Food: Preparation of potentially hazardous foods should be done so cooking the product to a higher that food is held not between 41-140°F whenever possible. If food must be prepared temperature. Corrective action between 41°-140°F, it can only be exposed in this temperature range for 4 hours total time, procedures will differ depending on the however, <2 hours total time is preferred. type of foods and the preparation practices used. Cooking: Food type Internal temperature* Holding time Record Keeping Beef roast (rare) 130°F 121 minutes Keeping records of the HACCP plan Beef roast (rare) 140°F 12 minutes and for monitored CCP’s is extremely Eggs, meat, fish 140°F 15 seconds ° important. It is a good idea to have Pork, game animals, 155 F 15 seconds records available for 1 year on location, ground beef Poultry, stuffed meats 165°F 15 seconds and for 3 years total. Good record *Microwave cooking Add 25°F ——— keeping helps to assure proper use of the HACCP program and the safety of Cooling: Potentially hazardous foods must be cooled from 140°F to 70°F within 2 foods that are served. During an hours, and from 70°F to 41°F within 4 hours (6 hours total time). inspection, a health inspector may ask Reheating: All foods must be reheated to an internal temperature of 165°F within 2 to see records for the HACCP program. hours. Foods may only be reheated once. Verification Hot Holding: After proper cooking, internal temperature should be maintained at ° Before, during, and after development >140 F prior to being served for all potentially hazardous foods. of a HACCP food safety prevention Cold Holding: Internal temperature should be maintained at <41°F prior to being program, it is important to verify that served for all for all potentially hazardous foods. the program is appropriate. HACCP (From 1995 FDA Food Code) programs can be verified by a represen- tative from the state or local health department. monitored, good records are being kept, Developing and implementing HACCP Once the program is in place, an and corrective action is taken when food safety prevention programs in employee in charge of food safety and needed. foodservice and food retail operations is quality should be assigned responsibility a useful systematic approach to improv- for the HACCP program. This Developing a HACCP Plan ing food handling practices and individual needs to verify that employ- There are several ways that foodservice decreasing the risk of . ees are performing tasks in the HACCP and retail food establishments may It is important to develop HACCP program. This person should also be develop a HACCP program. A programs using a team approach. responsible for training and educating practical approach is included in Figure Furthermore, it is important that employees on principles of food safety, 5. The most important aspect of the employees in foodservice and food retail food quality, and HACCP. Continuing process is to select a team of people to establishments, from the food manager education is the key for preventing risks develop the HACCP plan and describe to the front line worker, understand the of foodborne illness. a flow diagram of food throughout your importance of food safety. establishment. For assistance in Monitoring, good record keeping, and Temperature and time are most often corrective action are the heart of a HACCP program development, contact your local health department or local used as critical control point limits. HACCP program. These procedures Both temperature and time are easily work best when one person is in charge county extension office. of verifying that CCP’s are being 3 Figure 5. Steps in Designing a Figure 6. Product flow diagram: Hamburger patties. HACCP plan Receiving—> Cold Storage—> Patty Preparation—> Packaging—> Refrig. Storage 1) Set up a HACCP team (food manager, cook, local health inspector etc.). 2) Develop a flow diagram of the process (for each food that is served). Figure 7. Critical control points: Hamburger patties. 3) Perform a hazard analysis. CCP 1 CCP 2 CCP 3 CCP 4 4) Determine CCP’s. 5) Establish critical limits for CCP’s. Receiving—> Cold Storage—> Patty Preparation—> Packaging—> Refrig. Storage 6) Establish a procedure for monitoring CCP’s. 7) Establish plans for corrective action. HACCP Example 1: Preparation and Establish Critical Limits for CCP’s 8) Establish a method for record keeping. storage of hamburger patties in a Recall that critical limits in food retail 9) Train employees to understand. supermarket are usually defined as temperature(s) HACCP plans (How and Why!) Description: and time(s). Temperature and time 10) Implement the HACCP plan. limits can be set for each step in the Ground beef is received every 2 days in process (Figure 8). Refer to Figure 4 to 11) Verify that the HACCP plan is 5 lb packages. The ground beef is held effective. establish correct critical limits. For for a maximum of three days in a walk- receiving and cold storage, the ham- ° in cooler (set at 35-37 F). The morning burger meat should arrive and be butcher is responsible for weighing and monitored and temperature/time maintained at <41°F. Hamburger meat assembling 1/3 lb patties. Patties are parameters have been established for the should be maintained at <41°F during repackaged between wax paper, placed elimination, destruction and/or preven- patty preparation if possible. If not on a styrofoam tray, covered with a tion of growth of foodborne hazards. possible, limit patty preparation time to plastic film, and held at refrigerated Making sure that employees have good <2hrs. It may be better to work with storage until sold (Figure 6). personal hygiene, that employees take smaller batches of meat in order to measures to avoid cross-contamination, Hazard Analysis minimize the length of time at room and that the food establishment has an temperature. The primary concern with preparation effective cleaning and sanitizing and storage of raw hamburger patties is Monitoring CCP’s program in place are also important biological hazards. One should assume preventative measures to avoid The temperature of the ground beef that hamburger meat is likely to con- foodborne microbial illness. should be monitored upon receipt, tain harmful bacteria (i.e. Escherichia during cold storage, and periodically Although the latter measures are a big coli, Salmonella spp.). During patty during patty preparation with an part of food safety prevention, they are preparation, the meat could be further approved and calibrated food thermom- usually not part of HACCP. They are contaminated from contact with eter. If possible, upon receiving the part of Standard Operating Procedures infected food handlers that do not meat, check the time/temperature (SOP’s) or Good Manufacturing follow proper sanitary practices (i.e. records from the delivery truck. Practices (GMP’s). These issues are washing hands). generally not included in HACCP Corrective Action Determine CCP’s programs because they cannot be Here, corrective action needs to be During storage and preparation of monitored easily and critical limits have established if any of the CCP limits are ground beef patties, it will be important not been defined. Remember that not met. If the product is delivered at to control the growth of bacteria HACCP is not a stand-alone program. >41°F, or if records from the truck inherent to the hamburger. To do so, Assuring food safety relies on an indicate that the product was >41°F each step in the process (receiving, cold effective SOP (or GMP) program during distribution, the meat should be storage, patty preparation) would be coupled with a strong HACCP program. rejected. If meat is >41°F for >2 hrs considered a CCP (Figure 7). Safe during cold storage or patty preparation, temperature and time guidelines have the product should be discarded. been established at each step and are needed for the safety of the product.

4 Hazard Analysis Figure 8. Critical Control Point limits: Hamburger patties. Since the turkey roast is coming from a <41°F food processing plant, we assume that or they have taken appropriate measures <41°F <41°F 41-140°, <2hrs <41°F to eliminate chemical and physical hazards. The primary concern with a Receiving—> Cold Storage—> Patty Preparation—> Packaging—> Refrig. Storage raw processed turkey roast would be biological hazards. Raw poultry naturally contains biological hazards. A Figure 9. Record keeping: Hamburger patties. good example would be bacteria such as Salmonella spp. Determine CCP’s Date Time of CCP# CCP Temp. Time Action Initials Day limit(s) (°F) Yes/No Raw poultry is a potentially hazardous food that will naturally contain disease- 1/5/93 11:21 am 1 (Rec.) <41°F38°F——No causing microorganisms. Throughout 1/6/93 1:45 pm 2 (Stor.) <41°F37°F——No preparation and service, it will be 1/6/93 6:15 pm 3 (Prep.) <41°F or —— 4.5 hr Yes, important to keep the product properly 41-140°, <2hr 41-140 product stored, to cook the product thoroughly, discarded for cool foods to be served quickly, and 1/6/93 NA* 4(Stor.) <41°F NA* NA* NA* for “cold foods to be kept cold” and “hot foods to be kept hot.” It will be *NA - Data not available since product was discarded at CCP 3 (patty preparation time critical to control and monitor tempera- exceeded limit of 2 hrs). ture throughout all areas of the process that could allow survival and/or growth of harmful microorganisms. Critical Control Points for this process would include thawing, cooking, hot- Record Keeping HACCP Plan Example 2: Preparation holding, cooling, and cold-holding (Figure 11). At each of these points, Maintain records including date, time of and cooking of a frozen boneless safe temperature and time guidelines day, CCP#, CCP limit(s), temperature, turkey roast in a restaurant have been established. If these areas time (at temperature), corrective action, Description: are not controlled, serving this food initials of person recording data (Figure ° would likely lead to a health hazard, 9). As part of record keeping, if a A frozen (0 F) raw turkey roast is foodborne illness. deviation from the critical limit is received in an 10 lb package. Upon noted, there should be clear instructions receipt, the turkey is held frozen in the Control Points for this process would of what to do. restaurant until thawing in the cooler include receiving and frozen storage, ° (35-37 F) for 24-48 hours. The thawed which are standard for all frozen Verification turkey roast is cooked in a conventional products. The standard operating oven. Half of the roast will be sliced Verify that the HACCP plan is procedures for frozen foods would be to working. A supervisor in charge of food and served as a hot entree. The other check the temperature upon delivery to safety and quality should ensure that half of the roast is cooled and served see if it is <0°F and then store at <0°F. cold for sandwiches. Both foods are the HACCP plan is working. The Control points are mainly established supervisor should be checking that presented to the customer on a self- for food quality. Critical limits are not service buffet (Figure 10). CCP’s are being properly monitored and set for Control Points. that good records are being kept. It may be useful to submit your HACCP plan to the local health inspector to Figure 10. Product flow diagram: Turkey roast. verify that the HACCP plan is effective for assuring safe food. Hot Holding Receiving—> Frozen Storage—> Thawing—> Cooking—> or Cooling—> Cold Holding

5 Establish Critical Limits for CCP’s Figure 11. Critical Control Points: Turkey roast. Critical limits for the CCP’s defined CCP 3a above can be found in Figure 4. The Hot Holding first CCP is thawing (Figure 12). The CP1 CP2 CCP 1 CCP 2 Receiving—> Frozen Storage—> Thawing—> Cooking—> safest method to thaw the frozen turkey CCP 3b CCP 4b roast is in a refrigerator maintained at Cooling—> Cold Holding <41°F. Refrigerator thawing takes planning ahead. If the turkey roast is needed sooner, thawing of the packaged turkey roast can be done under running Figure 12. Critical Control Point limits: Turkey roast. water (<70°F) for <2 hrs. Microwave >140°F thawing is another option. However Hot Holding microwave thawing is more suitable for <41°F smaller food products (<2 lbs). If the or >165°F roast is microwave thawed, it needs to <70°F, <2hrs >15 sec. be cooked immediately after thawing. Rec.—> Froz. Stor.—> Thawing———> Cooking——> The next CCP is cooking. All raw poultry products must be cooked to an ° ° 140 -70 F, <2hr internal temperature of >165°F for >15 ° ° ° 70 -41 F, <4 hr <41 F sec. The process then divides into two Cooling————> Cold Holding separate steps. The part of the food that is to be hot held, identified as CCP 3a, needs to be held at >140°F. The other part of the food that is to be cooled and held cold is identified Figure 13. Record keeping: Turkey roast. through CCP’s 3b and 4b, respectively. The food must be cooled from 140 to 70°F in <2 hrs and from 70 to 40°F in Date Time of CCP# CCP Temp. Time Action Initials <4 hrs (total time of 6 hrs). After Day limit(s) (F) Yes/No proper cooling, the food needs to be ° 1/4/93 7:30 pm 1 (Thaw) <41F, or 37F —— No cold-held at <41 F. <2hrs, <70F cold room Monitoring CCP’s 1/5/93 10:00 am 2 (Cook) >165F, 15sec. 180F 15 sec. No Thawing will be the first CCP that needs to be monitored. If thawing in 1/5/93 1:25 pm 3a (Hot >140F 98F —— Yes - Hold) product the refrigerator, be sure to check that the refrigerator and the food is main- discarded tained well below 41°F. If thawing is 1/5/93 1:30 pm 3b (Cool) 140-70F, <2hr 38F at No done under cold running water, keep 70-41, <4hr 2:00 pm the turkey in its original plastic wrap (<2hrs) and place under cold (<70°F) running water. Make sure that thawing time is 1/5/93 2:30 pm 4b (Cold <41F 39F —— No less than 2 hrs. Hold) Cooking is the next important CCP that needs to be monitored. Be sure that the internal temperature of the cooked product is at least 165°F for >15 seconds. For hot-held product, monitor the internal temperature every 30-60 minutes. The temperature needs to be at least 140°F. For cooled, cold-held product, measure temperature during cooling to ensure that product is <41°F

6 within the guidelines described in References Figure 12. For cold-held product, Deibel, K. 1994. Enhanced food safety monitor the internal temperature every with HACCP. Medallion Laborato- 30-60 minutes. The temperature needs ries. Vol. 11, No. 1. to be below 41°F. Educational Foundation of the National Corrective Action Restaurant Association. 1993. If any of the CCP limits are exceeded, HACCP Reference Book. Educational corrective action must be taken. If Foundation of the National Restau- CCP limits associated with thawing, rant Association: Chicago, IL cooling, hot holding, or cold-holding Pierson, M. D. and D. A. Corlett. are not being met, the product should 1992. HACCP Principles and ° be discarded or reheated to 165 then Applications. Van Nostrand hot held. Keep in mind that foods may Reinhold:New York. be reheated only once and only if you can prove that foods are not between U.S. Department of Health and Human 41°-140° for >4 hrs (< 2 hrs is pre- Services, Public Health Services, Food ferred). If, during cooking, the turkey and Drug Administration. 1995. Food roast is <165°F, continue cooking until Code (1995). U.S. Department of 165°F for 15 seconds is obtained. Commerce. Springfield, Va. Record keeping Maintain records including date, time of day, CCP#, CCP limit(s), tempera- ture, time at temperature, corrective action, initials of person recording data. As part of record keeping, if a deviation from the critical limit is noted, there should be clear instructions of what to do.

Verification Verify that the HACCP plan is working. A supervisor in charge of food safety and quality should ensure that the HACCP plan is working. The supervisor should be checking that CCP’s are being properly monitored and that good records are being kept. It may be useful to submit your HACCP plan to the local health inspector to verify that the HACCP plan is effective for assuring safe food.

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Cooperative Extension work in Agriculture and Home Economics, state of Indiana, Purdue University, and U.S. Department of Agriculture cooperating; H. A. Wadsworth, Director, West Lafayette, IN. Issued in furtherance of the acts of May 8 and June 30, 1914. The Purdue University Cooperative Extension Service is an equal opportunity/equal access institution.