FOOD SAFETY PRINCIPLES IN DEVELOPING PRODUCTS FOR THE FOODSERVICE MARKET

FOOD SAFETY PRINCIPLES IN DEVELOPING PRODUCTS FOR THE FOODSERVICE MARKET Session 25: Enhancing product development success by combining food science and culinary arts PRESENTED AT IFT ANNUAL MEETING AND FOOD EXPO NEW ORLEANS, LOUISIANA, JULY 18, 2005 O. Peter Snyder, Jr., Ph.D. Hospitality Institute of Technology and Management 670 Transfer Road, Suite 21A St. Paul, Minnesota 55114 USA TEL 651 646 7077 FAX 651 646 5984 osnyder@hi-tm.com http://www.hi-tm.com 7/14/2005 IFT05-fd-safe-principles 1

RETAIL PROCESS INNOVATION The retail chef innovates new processes and products. However, today, the chef must adhere to FDA-dictated process controls whereby specified hazards associated with a process are not always identified; critical levels for safety are not identified; the Food Safety Objective is zero illnesses; and equipment selection is often limited to NSF. The FDA says, if a retail food operation implements HACCP and does its own scientifically correct process development, it can do any federal process. Unfortunately, the HACCP literature gives no specific food science principles for product innovation. This symposium is intended to a provide a source of HACCP information that retail food operators can follow to develop new processes that meet specific Food Safety Objectives. 7/14/2005 IFT05-fd-safe-principles 2

USING AMC-HACCP, AN OPERATOR CAN DO ANY PROCESS VALIDATED AS SAFE BY THE OPERATOR. Minimally processed, cook-store (for 45+ days) foods such as sous vide / vacuum-packed, chilled foods with shelf lives determined by the operator vs. cook-serve. Processes modified to conserve cooking and refrigeration energy Food holding 41ºF, 7 days; 45ºF, 4 days; 50ºF, 2.4 days; 55ºF, 1.7 days, etc. Selling food prepared in a home if the home cook is trained. Thawing on the counter at room temperature (USDA). Simplified dish machine operation. Simplified fruit and vegetable washing (modified dish machine). Pasteurizing all food beginning at 130ºF. Peking duck room-temperature skin drying, 12 hours. Garlic-flavored oil for the table Korean rice cakes, room-temperature display, 24 hours. Cooling food in 15 hours to 40ºF. Fingertip rinse procedure in 1 gallon of water. Pumping roasts and turkey up to 20% (USDA). Fermented foods: sausage, cheese, yogurt, sauerkraut, kimchee, beer, wine, vinegar. 7/14/2005 IFT05-fd-safe-principles 3

THE RAW FOOD CONTAMINATION PROBLEM 1370 7/14/2005 IFT05-fd-safe-principles 4

NATIONAL ADVISORY COMMITTEE ON MICROBIOLOGICAL CRITERIA FOR FOODS (NACMCF) Logic sequence for the application of HACCP to wholesale processing PREREQUISITE PROGRAMS: Form the HACCP team; identify the system, products, services, customers, and processes, GMPs, etc. PROCESS HACCP 1. Conduct the hazard analysis. Identify process steps with hazards and level of the hazard. (1) Do a risk analysis and decide which hazards are unacceptable risks. (1) 2. Apply HACCP decision tree to each step with unacceptable risks. Determine which steps are critical control points. 3. Establish critical limits for preventive measures associated with each CCP. 4. Establish CCP monitoring requirements. Establish procedures for using the results of monitoring to adjust the process and maintain control. 5. Establish corrective action to be taken when monitoring indicates that there is a deviation from an established critical limit. 6. Establish procedures for verification that the HACCP system is working correctly. 7. Establish effective record keeping procedures that document the HACCP system. Process step 1. CCP Y/N Chemical, physical, biological hazards 1, 2, 3, etc. Critical limits Monitoring procedures / frequency / person(s) responsible Corrective actions(s) / person(s) responsible Verification procedures / person(s) responsible HACCP records 7/14/2005 IFT05-fd-safe-principles 5

THE KITCHEN HACCP TEAM DOES A NACMCF-STYLE HACCP PLAN WITH RISK MANAGEMENT STEP CCP Step Description STEP B,C,P Hazard Analysis / Risk Assessment Not sig sig Hazard Control Monitoring / Self-Check Corrective Action (by HACCP team) Verification and Improvement 1. Specify ingredients and flow chart the process / recipe. 2. At each step, ask: a. Is there a B,C,P hazard that can be at a level to make people ill, and is this the correct step to control it? Is it cost effective to control? b. If yes, what validated control do we use? c. How does the cook monitor to verify control? d. If we lose control, what corrective action rules do we apply? e. How do we verify that we have control? 7/14/2005 IFT05-fd-safe-principles 6

FOOD OPERATIONS RISK CONTROL MANAGEMENT Risk = the likelihood of a hazard injuring a customer x the severity Risk management is the responsibility of the owner / manager / chef (not regulatory officials) to provide an Appropriate Level of Protection (ALOP) to their customers. Food liability insurance is for the residual low probability of an unanticipated event. Effective control of significant hazards is when a trained cook follows validated procedures to control hazards for an ALOP. The cook is then given positive reinforcement, and processes are evaluated periodically for improvement. 1904-ov&risk:food-op-haz-cont 7/14/2005 IFT05-fd-safe-principles 7

THE OCCURRENCE OF AN ILLNESS REQUIRES MANY ERRORS. Raw food is very contaminated, but very few meals cause illness. Why? P T = P 1 x P 2 x P 3 x P 4 x P 5 The farmer must have a colonized animal The fruit, vegetable, meat must become contaminated with a pathogen in harvest / slaughter In the kitchen, the pathogen must be given time to multiply (except Campylobacter spp.) OR the cook must crosscontaminate OR undercook The cook must not correct the problem OR management must not observe and prevent the problem The customer must be susceptible to the level of the pathogen, and the illness must be severe 7/14/2005 IFT05-fd-safe-principles 8

POTENTIAL HAZARDS IN THE FOOD CHEMICAL Poisonous Substances Toxic plant material Intentional additives Chemicals created by the process Agricultural chemicals Antibiotic and other drug residues Unintentional additives Sabotage / terrorism Equipment leaching Packaging leaching Industrial pollutants Heavy metals Radioactive isotopes Adverse Food Reactions (food sensitivity) Food allergens Food intolerances Metabolic disorder Pharmacological reactions Idiosyncratic reactions Anaphylactoid reactions PHYSICAL Hard Foreign Objects Glass Wood Stones Metal Packaging materials Bones Building materials Personal effects Functional Hazards Particle size deviation Packaging defects Sabotage Choking / Food Asphyxiation Hazards Pieces of food Thermal Hazards Food so hot that it burns tissue BIOLOGICAL Microorganisms and their Toxins Bacteria: vegetative cells and spores Molds (mycotoxins, e.g., aflatoxin) Yeasts (Candida albicans) Viruses and rickettsia Parasites Fish and shellfish as sources of toxic compounds Pests, animals (birds, insects and rodents) as carriers of pathogens Filth from insects, rodents, and any other unwanted animal parts or excreta 7/14/2005 IFT05-fd-safe-principles 9

PROCESS HACCP IS NOT JUST SEVEN PRINCIPLES HACCP has no process performance criteria / numbers. Applying HACCP principles, one uses food science to specify and develop process performance criteria and to set controls in a new process so as to achieve a desired consumer Appropriate Level of Protection (ALOP) / Food Safety Objective (FSO) (e.g., illness per 100,000 people; deaths per 1,000,000 people). Food from the farm Biological, chemical, and physical contamination (baseline) Distribution Processor / kitchen Ingredient specifications (to reduce level of hazards Hazard and risk analysis to determine significant hazards Control; to reduce significant hazards to an ALOP Monitoring to assure process stability and capability Food Safety Objective (FSO) Consumer Appropriate level of protection (ALOP) Process step example using process safety management language: Cook for a 5D reduction of Salmonella to get <1 Salmonella / 100 g (Control measure) (Performance criterion) (Performance objective) 7/14/2005 IFT05-fd-safe-principles 10

HAZARD FOOD SAFETY OBJECTIVES 7/14/2005 IFT05-fd-safe-principles 11

THE RETAIL FOOD SAFETY MANAGEMENT SYSTEM 7/14/2005 IFT05-fd-safe-principles 12

MENU INGREDIENT HAZARD ANALYSIS Mozzarella Cheese Sticks Potatoes, parfried French Fries Skillet Hashed Browns Mashed Onion Rings, parfried Onion Tanglers, parfried Corn Beef Hash Sausage Links, precooked Ham Boca Burger Cheese Pizza Turkey Breast, fully cooked Smoked Sausage Sausage Crumbles Nacho Meat Roast Beef Eggs, liquid pasteurized Kraft Macaroni and Cheese French Toast Batter (pasteurized ingred.) Pancakes (pasteurized ingred.) Waffles (pasteurized ingred.) Gravies (pasteurized ingred.) Soups Marinara Sauce Wing Sauce Stuffing Ingredients Supplier Makes Safe Grits Oatmeal Vegetables, frozen Coleslaw Mix Canned Fruits (e.g., Cranberry and Apple Sauce) Pico de Gallo Applesauce Swimmers Taco Chips Salsa Cheeses (e.g., American, Swiss, Cheddar, Parmesan, Cream Cheese, Cottage Cheese) Pickles BBQ Sauce Cocktail Sauce Butter Margarine Spreads (Garlic, Sweet Hickory) Honey Salad Dressings (e.g., coleslaw dressing, mayonnaise, tartar sauce, ranch dressing, etc.) Condiments (e.g., ketchup, mustard) Creamers Coffees Cocoa Teas Fruit Juices (e.g., orange, apple, tomato, lemonade) Soft Drinks (dispenser) Milk (Whole, 2%, skim, chocolate) Cream Assorted Bread Products Bagels Biscuits Apple Crisp Frozen Pies (Unbaked and prepared) Frozen Cakes and Brownies Oreo Cookie Crumbles Ice Cream Jams and Jellies Syrups (pancake) Syrups (for malts, sundaes etc.) Caramel Sauce Vinegar, Sugar (brown, powdered) Crackers and Croutons Apple Topping Ingredients Cook Makes Safe Baked Potato Chicken parts and strips Charleston Chicken Nuggets Chicken Breast Chicken Fried Steak Cod, battered Shrimp, breaded Bacon Hamburger, Junior and Regular Eggs (in-the-shell), over-easy, up, hard-boiled, poached Steak T-bone Sirloin Country Fried Steak Fresh Vegetables (e.g., Celery, Cilantro, Cucumbers, Onions, Peppers, Lettuce, Romaine, Mushrooms, Tomatoes, Parsley) Fresh Fruits (e.g., Lemons, Limes, Grapes, Raw Fruit Mix) 7/14/2005 IFT05-fd-safe-principles 13

PRODUCTS CAN BE GROUPED BY HACCP PROCESS Hazards, Critical Controls, Limits (USDA HACCP, 9 CFR 417) I II III IV V VI VII VII HACCP Process Not heat treated, not shelf stable. sashimi; lettuce and coleslaw salads; fruit salads; sprouts; yogurt; sauerkraut; kimchee; salsa Not heat treated, with secondary inhibitors, not shelf stable. corned beef Not heat treated, with inhibitors to make shelf stable. flour, nuts, salt, sugar, honey, spices and herbs, corn meal, oil and lard Not fully cooked, not shelf stable. Rare meat, fish, poultry; eggs, vegetables Not fully cooked, with inhibitors to make shelf stable. pepperoni; salami; ham; salted, dried fish; cheese; salad dressing; beer; wine Fully cooked, not shelf stable. hot or cooled, refrigerated ready-toeat food; meat, fish, poultry; fruits and vegetables, dairy Fully cooked, with inhibitors to make shelf stable. marinara sauce; pie fillings; smoked fish; canned, low-ph fruits and vegetables; dry cereals, pasta Commercially sterile, shelf stable. canned meat, fish, poultry; canned dairy products, canned vegetables Shelf life <14 days <14 days >2 years (chem. spoil) <14 days >2 years (chem. spoil) Hot <4 hours Cold 14-90 days >5 years >5 years 7/14/2005 IFT05-fd-safe-principles 14

MENU ITEMS GROUPED BY HAZARD AND CONTROL CATEGORIES (Assumes that prerequisite programs are effective.) 7/14/2005 IFT05-fd-safe-principles 15

QUALITY-ASSURED HACCP RECIPE PROCEDURES Recipe name: Production style: Written by: Date: SA/QA by: Date: Portion size (vol./wt.): Number of portions: Final yield (AS): Preparation time: Prepared by: Supervisor: Gp. # Ingred. # Ingredients and Specifications EP Weight % Edible Portion (EP) (wt. or vol.) As Served (weight Ingredients that could produce possible allergic reactions: Prerequisite Procedures SSOPs / GMPs. Control chemicals. Remove physical hazards from food. Double wash fingertips / personal hygiene (6-log reduction). Sanitize food contact surfaces (5-log reduction). Train. QC. Buy food and store. Pre-preparation 1. Get food for recipe, <3-log increase Listeria monocytogenes (PHF <41ºF). 2. Thaw <70ºF. 3. Do pre-prep. No time-temperature hazard. No CCP. 7/14/2005 IFT05-fd-safe-principles 16

QUALITY-ASSURED HACCP RECIPE PROCEDURES (cont'd) Preparation 4. CCP. If making salad with uncooked ingredients, double wash all fruits and vegetables to reduce vegetative pathogens 2 log. 5. CCP. Cook for 5-log Salmonella reduction (155ºF, 15 seconds). Hold / Serve 6. Hot hold, transport, serve. No growth of Clostridium perfringens (>125ºF). Leftovers 7. CCP. Cool to prevent <1-log increase of Clostridium perfringens (135 to 41ºF, <14 hours; <2 inches deep or 1-gallon pot). 8. Cold hold, <3-log increase Bacillus cereus. If making cold mixed salad, get all ingredients <50ºF before mixing (PHF <41ºF). 9. Throw leftovers away or hold <7 days and reheat to 165ºF, 15 seconds (<3-log increase Bacillus cereus). 10. CCP. For allergen control, do not combine / mix leftovers. Process step # Start food ctr. temp., ºF Thickest food dimension (in.) Container size HxWxL (in.) Cover Yes/No Temp. on / around food End food ctr. temp., ºF Process step time, hr./min. 7/14/2005 IFT05-fd-safe-principles 17

FOOD PROCESS FLOW CHARTING Industrial Engineering Symbols Ο D O T D I S = Operate (minimize) (12x) = Transport (minimize) (2x) = Delay/Stage (a CCP, minimize) (1x) = Inspect (optimize after each CCP) (2x) = Store (a CCP if other than at end) (1x) (CCP = Critical Control Point) Food is made safe to eat 7/14/2005 IFT05-fd-safe-principles 18

FOOD PROCESS FLOW CHARTING (cont'd) STEP DESCRIPTION CARD 7/14/2005 IFT05-fd-safe-principles 19

CHICKEN CACCIATORE RECIPE HACCP PROCEDURES AND RECORD 7/14/2005 IFT05-fd-safe-principles 20

CHICKEN CACCIATORE HACCP RECIPE FLOW O=operate D=Delay I=Inspect S=Store T=Transport 7/14/2005 IFT05-fd-safe-principles 21

FOOD ADDITIVES Colors and flavor additives Sugars Herbs Salt Monosodium glutamate Color and flavor preservatives Antioxidants Ascorbic acid BHA BHT Erythorbic acid Propionic acid Sodium erythorbate TBHq Tocopherols Chelating agents Disodium EDTA Polyphosphates Citric acid Fat Substitutes Simplesse Polydextrose Olestra Antimicrobials Salt Sugar Acids Nutritional additives Texture-improving Gums Starches Microcrystalline cellulose Carboxymethylcellulose Polydextrose Anticaking agents Dough conditioners Emulsifiers Humectants Meat tenderizers Nitrates and Nitrites Sulfites Irradiation Indirect additives Production aids Adjuvants Sanitizers Paper board components Adhesives and coatings Polymers 7/14/2005 IFT05-fd-safe-principles 22

INGREDIENTS THAT CAUSE ADVERSE FOOD REACTIONS Cow's milk Legumes (includes peanuts) Crustacae, mollusks Fish Corn Eggs Wheat Tree nuts Food Allergens Food Intolerances Acids Alcohol Antioxidants Benzoates Caffeine Chili Food colorings Aza dyes Fructose Glutamates Capsaicin Histamine Nitrates Pepper Phenolic substances Sorbitol, natural sugars The consumers must tell you that they are sensitive. 7/14/2005 IFT05-fd-safe-principles 23

SOME SOLUTES THAT ARE WATER ACTIVITY MODIFIERS Polydextrose Lactose Sucrose DE 42 Maltose Glucose / Fructose Lactic Acid Propylene glycol KCl PEG 600 Lysine Ornithine Tartaric Acid Proline Malic Acid Xylose Mannitol Urea PEG 400 Lactulose Citric Acid Maltose Alanine Sorbitol Glycerol NaCl Glycine 7/14/2005 IFT05-fd-safe-principles 24

ANTIMICROBIAL ACTIVITY OF SPICES Antimicrobial Activity Strong Medium Spice Cinnamon, clove, mustard Allspice, bay leaf, caraway, coriander, cumin, oregano, rosemary, sage, thyme Weak Black pepper, red pepper, ginger Adapted from: Zaika, L.L. 1988. Spices and herbs: Their antimicrobial activity and its determination. J. Food Safety. 9:97-117. 7/14/2005 IFT05-fd-safe-principles 25

ORGANIC ACIDS AND ESTERS FOOD PRESERVATIVES 7/14/2005 IFT05-fd-safe-principles 26

PROCESS QUALIFICATION A qualified process is one that the cook can demonstrate in operation that all necessary procedures, training, documentation, measurement, controls, and checks and balances are in place to ensure that the process can produce uniform-quality, safe food, even under stress conditions. Until the performance of the process can be predicted, it is not in control. To predict, the key process variables must be known, be controlled, and be repeatable. Correction When you find a problem, remove the ROOT CAUSE of the problem. A "better" process means: USL-X More stable: C pk >1; More predictable; Safer = 3σ Common and special causes known; Special causes being reduced Waste being reduced Faster production Better customer satisfaction 7/14/2005 IFT05-fd-safe-principles 27

PROCESS VALIDATION PEER-REVIEWED RESEARCH REPORT [Author(s)] Introduction What is the process; what is the hazard; and what is the purpose of the report? Methods How were samples prepared? What microorganisms were used and source? What additives were used? How was the test conducted and controlled? How were the results measured? Results What were the data from the study, and how uniform were results? Discussion Discuss results in terms of the purpose of the study Conclusions Was or was not the hazard effectively controlled? Summary Date, Organization 7/14/2005 IFT05-fd-safe-principles 28

SUMMARY Raw food will always be contaminated. The water and dirt farms are not sterile. The cook must be able to look at food and decide what needs to be done to make it safe. Humans must eat pathogens at a safe level to maintain immune systems. Lawsuits for alleged illness will continue to increase. The cook / chef is the person who develops recipes and must be ready to validate and prove that he/she produced a safe food. Government retail food inspection does not certify that the food served is safe. Inspectors must empower managers and cooks to do self-control and "work themselves out of a job." Safe food starts with the menu. The chef must "HACCP" the recipes and train employees to do tasks with zero defects. The chef must innovate new process. HACCP is the procedure for self-certification. The chef must have a HACCP team and be improving processes and removing problems. 7/14/2005 IFT05-fd-safe-principles 29