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HACCP in Your School Warehouse Employees Revised April 2012 In accordance with Federal Law and U.S. Department of Agriculture policy, this institution.

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Presentation on theme: "HACCP in Your School Warehouse Employees Revised April 2012 In accordance with Federal Law and U.S. Department of Agriculture policy, this institution."— Presentation transcript:

1 HACCP in Your School Warehouse Employees Revised April 2012 In accordance with Federal Law and U.S. Department of Agriculture policy, this institution is prohibited from discriminating on the basis of race, color, national origin, gender (male or female), age, or disability. To file a complaint of discrimination, write USDA, Director, Office of Adjudication, 1400 Independence Avenue, SW, Washington, D.C or call toll free (866) (Voice). Individuals who are hearing impaired or have speech disabilities may contact USDA through the Federal Relay Service at (800) ; or (800) (Spanish). USDA is an equal opportunity provider and employer.(866) (800) (800)

2 Why Hazard Analysis Critical Control Point (HACCP)? To prevent foodborne illness in North Carolina schools. Foodborne illness –Caused by eating contaminated foods or beverages Each year there are: –48 million cases of foodborne illness –128,000 hospitalizations –3,000 deaths 2 - in -

3 Food-as-foe 3 Mason Jones Dec. 24, Oct. 6, 2005 Brianna Kriefall 3 year old

4 What makes us ill? ① Chicken ② Meats ③ Ground meats ④ Fin fish ⑤ Shellfish (Consumers response, Environics, 2005) ① Produce ② Poultry ③ Beef ④ Eggs ⑤ Seafood (CDC, 2009) 4

5 What causes foodborne illness? ① Food from unsafe source ② Inadequate cooking ③ Improper holding temperature ④ Contaminated equipment ⑤ Poor personal hygiene Who is at risk? –Infants –Toddlers –Elderly –Pregnant women –Immunocompromised –Taking specific medications 5

6 What food causes illness? Any food can cause foodborne illness –Even non-time/temperature control for safety foods Characteristics of a time/temperature control for safety (TCS) food: –Low acid –Moist –Contains protein 6 Keep time/temperature control for safety food out of the temperature danger zone!

7 Temperature danger zone When food is in the danger zone, harmful bacteria can grow, multiply, and possibly cause infection Bacteria can double in number in as little as 20 minutes 7

8 Bacteria can be transferred from one food to another if food is not properly stored Store raw food below cooked or ready-to-eat food Properly cover foods Cross contamination 8 Whole beef, fish, and pork Ground meats and fish Whole and ground poultry Ready To Eat foods Leftover foods

9 Employee Policies 9

10 Employee policies Uniform policy –Closed/steel toed boots –Back braces –Gloves Hair and nails trimmed 10

11 Basics of handwashing ① Wet hands with arm water ② Apply hand soap ③ Scrub for at least seconds, while cleaning under fingernails and between fingers ④ Rinse thoroughly under warm running water ⑤ Dry with a single-use paper towel or warm-air hand dryer ⑥ Use paper towel to turn off the water faucet and to open the bathroom door when returning to work 11 **Remember that hand sanitizers are not a replacement for effective and proper hand washing.**

12 When to wash hands After using the bathroom After coughing, sneezing, smoking, eating, drinking or touching body Before putting on gloves After any clean up activity After handling garbage or trash Do not handle food with bare hands if you have a sore that contains pus or that is infected Cover affected area with a bandage, a finger cot, and then a single-use glove 12

13 Reporting diagnosed foodborne illness If you have been diagnosed with one of the following foodborne illnesses, report it to your manager: –Hepatitis A virus –E. coli O157:H7 –Salmonella Typhi –Shigella spp. –Norovirus 13

14 Exposure to FB illness Exposure to or suspicion of causing any confirmed outbreak involving the above illnesses A member of your household is diagnosed with any of the above illnesses A member of your household is attending or working in a setting that is experiencing a confirmed outbreak of the above illnesses 14 **Remember – sick workers can contaminate food and make others sick.**

15 Workbook Example Employee Health Policy Agreement Warehouse - HACCP In Your School Manual Page 4 15

16 Thermometers 16

17 Thermometers 17

18 Checking your thermometer Check the accuracy of all thermometers: –Daily For calibration, prepare in advance –Purchase ice and store in cooler –Container to hold ice If not correct, calibrate 18

19 Calibration Boiling water method Ice-point method 19

20 Cleaning and sanitizing thermometers The probe or stem of a thermometer must be cleaned and sanitized before it is used If only measuring the temperature of ready-to- eat food, the probe or stem only needs to be cleaned between uses 20

21 Facility and Storage Preventing cross contamination Controlling time and temperature 21

22 Food Labels Do not remove the labels from commercially processed food If removed, label the container with the name of the contents Date food items with the month and year Fresh produce should be dated with month and day 22

23 Temperature of storage units Refrigeration –Must keep food at 41°F or colder –Air temperature should be 39°F or colder Freezer –Must keep food at 0°F or colder –Air temperature should be 0°F or colder –Keep floors dry and clean Dry storage –Best if temperature is between 50°F and 70°F –Humidity level should be between 50% and 60% 23

24 Storage of cleaning chemicals Improperly stored chemicals can possibly contaminate food Store separate from food, equipment, utensils, linen, and single-service and single-use items 24

25 Material safety data sheets Occupational Safety and Health Administration (OSHA) requires a Material Safety Data Sheet (MSDS) for all chemicals On every MSDS, be familiar with the following sections: –4.0 Fire and explosion data –5.0 Reactivity data –6.0 Spill or leak procedures –7.0 Health hazard data –8.0 First aid –9.0 Protective measures –10.0 Additional information/precautions 25

26 First In, First Out (FIFO) FIFO ensures proper rotation of foods in storage When foods are received, put the oldest in the front and the newest in the back Past-dated foods will lose their quality and sometimes become unsafe Inventory cycle 26

27 Salvaged items Providing a separate and labeled storage area for salvaged items –To be taken to Food Bank if possible Implementing procedures for handling and removal of salvaged, expired, damaged, or contaminated foods Disposition of these food items must also be documented 27

28 Are these acceptable? 28

29 How about this can? 29 Straight sides Undented seams Flat ends which curve slightly inwards Choose a can that has these features:

30 Cross-contamination in storage Bacteria can be transferred from one food to another if food is not properly stored Store raw food below cooked or ready-to-eat food Properly cover foods 30

31 Proper storage to prevent contamination Whole beef, fish, and pork Ground meats and fish Whole and ground poultry 31

32 Storage layout and cleaning Cleaning is the process of removing food and other soils Maintaining an unobstructed inch distance from walls to pallets Food products stored off floor by 6 inches or on pallets Pick up debris and sweep floors –Broken pallets, plastic wrap, etc 32

33 Application Exercises Warehouse - HACCP In Your School Manual Page 9 33

34 Equipment Preventing cross contamination 34

35 Preventative Maintenance Preventive maintenance tasks for your facility may include: –Cleaning condensers of refrigeration and freezer units –Defrosting freezer units –Oiling and lubricating moving parts of equipment. –Changing HVAC filters if applicable –Schedule fire suppression system –Schedule fire extinguisher inspection –Check cords and plugs for equipment operated by electricity –Maintenance of transport vehicles and equipment 35

36 What preventative maintenance should be scheduled? 36

37 What preventative maintenance should be scheduled? 37

38 Integrated Pest Management 38

39 Pest management Exclusion –Deny pests access to: Food Shelter Dumpsters and Recycling Area –Keep area clean –Locate dumpsters away from doors –Keep lids closed –Use trashcan liners –Empty and clean trash frequently 39

40 Pest management Insecticide application –Leave the job to the professionals –Avoid contaminating food –Use baits for ants and cockroaches Traps and baits –Use for insects and rodents –Check rodent traps daily –Leave rodent baiting to outdoor areas and to the professionals 40

41 Pest management Inspect and date all deliveries Discard or return infested or expired products Clean up spills as soon as possible 41 FIRST IN FIRST OUT

42 Label and MSDS 42

43 Record keeping Keep track of pest problems and measures taken to correct those problems 43

44 Receiving Purchasing from approved, reputable suppliers 44

45 Receiving Check delivery schedule Reconcile the amount of product received with the amount of product ordered Condition of delivery vehicle –Clean, good repair, proper temperature, no insects, no rodent droppings, and no meat juices on the floor 45

46 Receiving Organize storage space before deliveries Inspect food items to minimize the risk for foodborne illness and liability –Insert a food thermometer between 2 packaged products to check the temperature –Check dates of perishable goods –Mark with date arrival or use by date Inspecting deliveries for –Tampering, discoloration, pinholes, leakage –Unusual packages –Contamination (rodent activity or insects) –Proper temperatures (receiving log) 46

47 Receiving Unloading food items –Frozen first, refrigerated second, and dry goods last Substandard food items (Rejection policy) –A record should be kept of rejected food items –Photos should be taken if necessary 47

48 Temperature danger zone When food is in the temperature danger zone, harmful bacteria can grow, multiply, and possibly cause infection Bacteria can double in number in as little as 20 minutes 48

49 Workbook Tables Criteria for Accepting/Rejecting a Food Delivery Warehouse - HACCP In Your School Manual Page14 49

50 Criteria for Accepting or Rejecting a Food Delivery 50 FoodCriteria for Accept Delivery Raw meat and poultry 41°F or colder, visible USDA inspection stamp, reddish pink color or no odor, packaging clean and no tampering EggsShell eggs at 45°F or colder, liquid eggs at 41°F or colder, clean and uncracked, no tampering Fresh produceClean, in good condition and no tampering, if cut or processed must be 41°F or colder Dry foodsClean packaging and no tampering and no signs of pest infestation Canned foodsClean container and no tampering, label intact, no rust or corrosion, no buldges, no sharp dents or on the seam

51 Application Exercises Warehouse - HACCP In Your School Manual Page 15 51

52 Shipping 52

53 Pre loading process Check to make sure the truck is clean and remove any debris Turn on cooler at least 45 minutes Items to be loaded are sorted and staged 53

54 Loading Wheels are chocked Dry products first followed by refrigerated and then frozen items Load to minimize damage and movement during transportation 54

55 Unloading Travel time with/without refrigeration (temperature) Multi-stop delivery process Kitchen staff available to receive product Unload with hand trucks Store all product in appropriate location to prevent cross contamination 55

56 Catering Prepared food is handled to minimize contamination during transportation –Vehicles shall be maintained in a clean, sanitary condition Temperature monitoring –Cold foods cold < 41°F –Hot foods hot > 135°F Food in transit must be protected from contamination and must meet the temperature requirements noted above Proper storage at location 56

57 Sanitation Preventing cross contamination 57

58 Cleaning Cleaning is the process of removing food and other soils Cleaning agents:  Detergents  Solvent cleaners  Acid cleaners  Abrasive cleaners 58

59 Sanitizing Sanitizing is the process of reducing the number of microorganisms that are on a properly cleaned surface to a safe level Sanitizing agents only work on properly cleaned and rinsed surfaces 59

60 Locations Floors, trashcans, utility carts/dollies, storeroom and shelving Hand sink, ice machine Walk in refrigerator and freezer Transport vehicles 60

61 How this process works ① Washing helps loosen soils and other organic matter from the surface ② Detergent and scrubbing also helps break the adhesion of microorganisms to the surface 61 Iowa State University Extension, June 2011

62 How this process works ③ Rinsing removes loosened soil and detergent from the surface  This step is important because organic material and detergent can bind up sanitizer making it less effective 62 Iowa State University Extension, June 2011

63 How this process works ④ Applying the sanitizer to clean surfaces actually provides a ‘kill’ step for reducing the number of microorganisms 63 Iowa State University Extension, June 2011

64 How this process works ⑤ The surface is not completely free of microorganisms, but the number is greatly reduced 64 Iowa State University Extension, June 2011

65 Measuring Sanitizer Strength A test kit that accurately measures the concentration of sanitizing solutions must be available The strength of sanitizing solutions must be measured frequently during use 65

66 Material safety data sheets Occupational Safety and Health Administration (OSHA) requires a Material Safety Data Sheet (MSDS) for all chemicals On every MSDS, be familiar with the following sections: –4.0 Fire and explosion data –5.0 Reactivity data –6.0 Spill or leak procedures –7.0 Health hazard data –8.0 First aid –9.0 Protective measures –10.0 Additional information/precautions 66

67 Workbook Table Cleaning Schedule and Procedures Warehouse - HACCP In Your School Manual Page 7 67

68 How would you clean/sanitize these items? 68

69 How would you clean/sanitize these items? 69

70 Food Defense 70

71 Food defense Protect food from intentional contamination –Disgruntled current or former employee –Members of terrorist or activist groups posing as: cleaning crew, contractors, truck drivers, visitors, and utility representatives Primarily about limiting access to products Understanding what might happen and monitoring who has access to food Identify your vulnerabilities and implement food defense solutions

72 Exterior security measures Providing adequate lighting around the outside of building Accounting for all keys to establishment Locked doors, gates, roof access, windows –Emergency exits Loading dock access Prevent environmental contamination and infestation by insects or vermin 72

73 Interior security measures Accounting for all keys to establishment Providing adequate lighting –Emergency lighting and alert system Checks/reports suspicious packages –Bathrooms, closets, etc Cleaning supplies, pest control chemicals and other hazardous material 73

74 Personnel security measures Restricting entry to the establishment –Requiring proof of identity –Escorting visitors Employee vehicles are identified and lockers inspected Training employees on emergency evacuation procedures –Include a map and meeting location to account for all employees 74

75 Incoming Shipments Restricted access to loading docks All deliveries checked against the roster of scheduled deliveries Returned goods are segregated and records are maintained 75

76 Handling a Food Recall 76

77 Food recall Occurs when there is reason to believe that a food may cause consumers to become ill. Can be initiated by a: –Food manufacturer or distributor –Government agency (USDA or FDA) Causes can be: –Discovery of an organism in a product –Discovery of a potential allergen in a product –Mislabeling or misbranding of food 77

78 Snokist canned apple sauce In May 2011, 9 North Carolina kids reported vomiting and nausea after eating Snokist apple sauce. The canned apple sauce had faulty seals and was possibly reworked moldy applesauce. Product oozing out of cans and employees still served to students.

79 Snokist recall 79

80 Food recall issued Review the food recall notice and specific instructions Communicate the food recall notice to school cafeterias –Via , phone, etc Hold the recalled product –Physically segregate the product (including open containers, leftovers, etc) Mark recalled product ‘Do Not Use’ and ‘Do Not Discard’ –Inform the entire staff 80

81 Food recall Do not destroy any USDA commodity food without official written notification from NCDA, USDA FSIS, or State/Your County health department Inform Your County PSS’s public relations coordinator of the recalled product Identify and record whether any of the product was received in Your County PSS, locate the implicated product by cafeteria site –Verify that the food item bears the product identification code and production date listed in the recall notice 81

82 Food recall Obtain accurate inventory counts of the recalled product from every cafeteria site, including the amount in inventory and amount used Account for all recalled product by verifying inventory counts against records of food receiving at the feeding site Notify feeding site staff of procedures, dates, and directions to be followed for the collection or destruction of recalled product Consolidate the recalled product as quickly as possible, but no later than 30 days after the recall notification 82

83 Conform to the recall notice Report quantity and site where product is located to manufacturer, distributor, or NCDA for collection –If USDA commodity must be submitted to NCDA within 10 days of recall Obtain necessary documents from NCDA for USDA commodity foods 83

84 Conform to the recall notice Complete and maintain all required documentation related to the recall including –Recall notice –Records of how food product was returned or destroyed –Reimbursable costs –Public notice and media communications –Correspondence to and from the public health department and NCDA 84

85 Power Outage Preventing cross contamination Controlling time and temperature 85

86 Refrigerators Note the time the outage occurred Food should be safe as long as the power is out no more than about 4 to 6 hours Leave the door closed –When open needed cold air escapes, allowing the foods inside to reach unsafe temperatures 86

87 Freezers Leave the freezer door closed With the door closed, food in most freezers will stay below 41°F for up to 3 days –Full freezer should keep food safe about 2 days –Half-full freezer, about 1 day You can safely re-freeze thawed foods that still contain ice crystals and are 41°F or less 87

88 Thawing Freezing does not kill microorganisms, but it does slow their growth During a power outage, frozen food can begin to thaw, resulting in the outer surface warming up and allowing harmful microorganisms to grow The time it takes for food to thaw depends on: –Amount of food in the freezer –Kind of food –Temperature of the food –Size and insulation of freezer 88

89 When in doubt, throw it out! If it appears the power will be off for more than 6 hours –Ice, dry ice, or frozen gel packs may be used to keep TCS foods at 41°F or below Moving refrigerated food to a walk-in freezer or obtaining a refrigerated truck are other options to keep food safe Food should not be transferred to private homes 89

90 Discarding items Foods that can safely be stored above 41°F for a few days include: –Whole non-cut fresh fruits and vegetables –Condiments such as ketchup, mustard, relishes, barbecue sauce, soy sauce, olives –Jams and jellies –Bread, rolls, bagels, cakes (without cream or custard), cookies and muffins –Most hard cheeses including parmesan, asiago and pecorino 90

91 91

92 Power restored Identify and discard TCS foods that may have been above above 41°F for 4 hours Check the internal food temperatures using a food thermometer and record the temperature. If practical, separate packages of food in refrigeration units and freezers to allow for faster recooling. The refreezing of food may affect the quality and should be used within a short period of time. 92

93 Acknowledgments Food Safety and HACCP Information Prepared by: –Benjamin Chapman, Ph.D., NCSU, 2012 –Audrey Kreske, Ph.D., NCSU, 2012 Pest Control Information Updated by: –Michael Waldvogel, Ph.D., NCSU,


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