THE ROYAL SOCIETY FOR PUBLIC HEALTH EXAMINATION FOR THE LEVEL 4 AWARD IN FOOD SAFETY MANAGEMENT in MANUFACTURING Paper Two: CASE STUDY Date xxxxxx IMPORTANT READ THE FOLLOWING INSTRUCTIONS CAREFULLY 1. Candidates should enter their candidate number in the space provided on the cover of the answer book. No signature or name should appear on the answer book. 2. You should write all of your answers in the answer book provided. 3. You are allowed ONE hour to complete the case study. 4. This paper and your answer book must be left on your desk at the conclusion of the test.
A pizza manufacturer produces frozen pizzas for the retail market, which are cooked and served by the consumer. He currently produces a limited range of pizzas, with tomato, cheese, mushroom and pepper toppings only. However, he will shortly be extending his range to include ham, chicken and beef toppings. The manufacturer will therefore have to modify his existing food safety management procedures to take account of the new products. His current ingredients are: Dough ingredients: Pizza flour, water, yeast, sugar, vegetable oil, salt, skim milk powder, lecithin, cornstarch, shortening, sodium aluminium phosphate. Pizza sauce -water, tomato paste, pizza seasoning, vegetable oil Cheese products: Mozzarella, Parmesan, Cheddar Garnish mix: canned mushrooms, quick frozen mushrooms, dehydrated onion, quick-frozen strips of red peppers. The production premises is a medium scale food manufacturing plant that can be expected to operate comprehensive prerequisite programmes.
1. What food safety hazards are associated with the current ingredients? 2. The manufacturer s current process-flow chart is attached, showing the critical control points that have been identified. Explain why each of these steps has been identified as a critical control point. 3. Outline the controls that should be in place at each of the critical control points and state how these should be monitored. 4. The manufacturer decides to add a single extra step to his process flow diagram for the addition of the meat to the pizzas. This will be between steps 6 (sauce application) and 7 (cheese application). 5 marks All of the ingredients are added to the pizza from hoppers. What food safety hazards does this present and how might they be controlled? 5. The manufacturer decides he has three options for the production of his new range of pizzas: 30 marks i) buying in all the meat ready cooked, and slicing it before putting it into the hoppers ii) buying in the ham ready cooked, the chicken as frozen raw chicken breasts and the beef as frozen raw cuts of meat. The chicken and beef will then be cooked and sliced on-site before putting into the hoppers iii) buying in the meat as (ii) above, and adding the chicken and beef to the pizzas as raw meat which will be cooked by the consumer. Discuss these options in terms of the food safety hazards that they present and the control measures that will need to be introduced
6. The manufacturer decides to cook the chicken and beef on-site. 10 marks Draw up a process-flow diagram for the preparation and cooking of the chicken. Take as your starting point the delivery of the raw frozen chicken breasts to the factory, ending with the addition of the cooked chicken to the pizza base. You should include in your diagram any critical control points. 7. The manufacturer decides that extending the range of his products will increase the food safety risks within his factory, and that to cope with these increased risks the food safety culture of his staff will need to be improved. How could this be achieved? 10 marks
Process Flow Chart for Pizza Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Step 12 Receiving Ingredients CCP Storage of ingredients Dough preparation Dough baking Cooling Sauce application Cheese application Garnish application Freezing Labelling and wrapping (CCP) Metal detection (CCP) Packing and Dispatch