HACCP and Food Recall Essentials for School Nutrition Professionals

HACCP and Food Recall Essentials for School Nutrition Professionals Cindy Rice, RS, MSPH October 19, 2016 Nuts and Bolts Workshop DESE Framingham State College

Food Safety Essentials Falling dirt Insects flying 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

Learning objectives Understand the main hazards to food Identify TCS foods and their characteristics Know the major allergens and control measures

Major Risks to Food Biological Chemical Physical

Foodborne Illness 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

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 foods 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

Pop Quiz 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

Flow of Food

3 Main Hazards to Food Poor Personal Hygiene Cross-Contamination Time-Temperature Abuse

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 140 F Bacteria grow to dangerous levels in TDZ (Temperature Danger Zone) 41 F 140 F 2 hour maximum for Schools Discard 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

Food Allergies

Food Allergens The Big 8 Eggs Dairy Wheat Soy (tofu) Tree nuts Peanuts Fish Shellfish Protein in the food is what causes the allergic reaction Gluten, Lactose Intolerances- sensitivities

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

Pop Quiz 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

HACCP Food Safety Systems

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

Flow of Food

Why HACCP? Purpose: Identify possible hazards in the flow of food ahead of time

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 Principle Two Principle Three Principle Four Principle Five Principle Six Principle Seven Conduct a Hazard Analysis Determine the CCPs Establish Critical Limits Establish Monitoring Procedures Take Corrective Action Verify that the system works Record keeping

1. Conduct Hazard Analysis Identify potentially hazardous foods from your menu Determine which are significant and must be addressed in HACCP plan

Roast turkey Determine which are significant and must be addressed in HACCP plan

Hazards Control them at each step

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

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 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 CCP 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 Staff Procedures Proper equipment Reputable suppliers

Pop Quiz 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

PROCESS HACCP School Foodservice USDA guidelines Restaurants 47

Learning objectives 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 48

1. Develop Prerequisite Programs Procedures that address basic operational and sanitation conditions in an operations 49

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

Standard Operating Procedures SOPs Written specifically for your school Who? What? When? Where? How? Why? 51

2. Identify Hazards in foods Bacteria Viruses Poor personal hygiene Physical objects Chemical contamination 52

3. Make a Flow Chart for all foods Diagram that shows the step-by-step progression or flow of food through a food preparation process, in sequential order 53

Use the recipe and/or preparation procedures to lay out food flow into major operational steps... 54

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 55

Review Food Flow # Trips through Temperature Danger Zone Process 1 Process 2 Process 3 56

Review Food Flow and TDZ 140 F Process 1 Process 2 Process 3 57

Process 1: Food Preparation with No Cook Step Flow of food Receiving Store Prepare Hold Serve Examples Sandwiches w/ RTE Fillings Canned Tuna Canned Chicken Deli Meat Salads Fresh fruits NO complete trip through Danger Zone 58

Process 2: Preparation for Same Day Service Flow of food Receive Store Prepare Cook Hold Serve Examples (all for immediate service) Hamburgers Roast turkey Stir fry dishes 1 complete trip through Danger Zone 59

Process 3: Complex Food Preparation 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 2 or more complete trips through Danger Zone

What s the Process Group? 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

Fried Chicken Chicken is deep fried for 15 minutes at 400 o F. Chicken is placed to metal sheet pan and placed under a heat lamp/steam table until served. 62

Fried Chicken Chicken is placed with clean tongs, onto plates, and onto students trays 63

FRIED CHICKEN How many times through Danger Zone? RECEIVE STORE THAWING SERVE HOT HOLD COOK Process 2: Preparation for Same Day Service 64

TUNA SALAD How many steps through Danger Zone? 0 RECEIVE STORE ASSEMBLE SERVE STORE CCP Process 1: Food Preparation with NO Cook Step What are CCP(s)? Critical limits?

Chicken salad (made in-house from scratch) How many steps through Danger Zone? RECEIVE STORE COOKING CCP SERVE PREPARE COOLING CCP Process 3: Complex Food Preparation What are CCP(s)? Critical limits? Other way to make it a different Process?

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) 67

Chicken casserole, Taco filling How many steps through Danger Zone? RECEIVE STORE COOKING CCP SERVE REHEATING CCP COOLING CCP Process 3: Complex Food Preparation What are CCP(s)? Critical limits? SOP S?

LET S REVIEW 69

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 involve no Cook step? Process 1 Process 2 Process 3

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

Update and re-validate plan with every change in process, ingredient, menu item

HACCP System Success To protect our children!

Responding to Food Recalls

. Kiwis...Italy Cream...Ireland Apricots...Turkey Hazelnuts...Asia Cocoa beans... Amazon Raspberries...Canada Strawberries...California

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

Common causes Undeclared allergen Detection of hazard or disease-causing organism Misbranded or mislabeled product

3 Classes of Recalls Class 1 Reasonably likely to cause illness E.coli (produce) Salmonella (peanut butter) Listeria (RTE) Class 2 Yellow dye # 5 Class 3 Remote possibility of illness 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 Regulatory agency receives notice On-site managers notified Customers notified Works with supplier for proper actions Coordinates with industry response Response actions by staff Product return, disposal Product removal, return

Product identification Company Name Brand Name Case Markings Establishment number (for meat, poultry, or eggs) Product Markings Note: UPC Code is not be adequate

Recall notice Product description Use-by date Distribution area

Bulk Item Challenges LOT # Use-by date

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 USDA FNS NO RAS/ WBSCM NPA Processors SDA(Food Safety Contact) SENS Customers State Contracted Distributors In-state Processors Other Entities RAs

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

Disposal IF NECESSARY Discard in a manner that prevents use or eating Follow guidelines by USDA, FNS, manufacturers Document discarded products in recordkeeping system

Product Destruction Form Name of State Agency Name of Recipient Agency Commodity # Cases Destroyed Contract # Destruction Method Witnesses Print Name Signature Date Destruction Observed Witness 1 Witness 2 School District Contact Information:

Solid Waste Disposal Program information at: www.epa.gov/epawaste/wyl/stateprograms.htm

Food recalls are A. Voluntary B. Mandatory C. Timely D. Standardized

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

Training staff 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

Conducting a Mock Recall in a School Nutrition Operation

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

Types of Records for USDA Foods Inventory Distribution Storage Disposal

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 USDA AMS reviews and approves expenses USDA AMS submits public voucher for payment SDA combines all requests for State & reports data in WBSCM USDA FNS National Office reviews SDA s claim & documentation SDA reimburses RAs (SFAs, processors, distributors) SDA submits public voucher, FSA-21, & supportive documents USDA FNS Regional Office reviews SDA s claim & documentation USDA FNS NO coordinates product replacement or entitlement reimbursement with SDA

Thank you! Cindy Rice, RS Eastern Food Safety cindy@easternfoodsafety.com