2902: TECHNOLOGY
OF HACCP-BASED, CHILLED FOOD PRODUCTION SYSTEMS
Detailed Table of Contents
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Chapter 1:
Pasteurized-Chilled (Minimally Processed) Foods vs. Commercially
Sterilized
Foods
Introduction
Commercially
Sterilized Foods
Pasteurized-Chilled
(Minimally Processed) Foods
What
are minimally processed foods?
Sous
vide / Chilled Foods
Storage
Stability
Two
Basic Packaging Aspects for Chilled Foods:
Package-Cook or Cook-Package
The
History of Chilled Food
Chilled
Food Production Factors
Chapter 2:
Total Quality Management vs. Government Regulations
Management: The
Critical Factor in Quality
Total
Quality Management
Government
Regulatory Agencies
Regulating
Quality
Regulating
Safety and Fraud
ISO
9000 and ANSI/ASQC Q91-1987
Outline
of ISO-9000 Development Standards
The
Malcolm Baldrige Award for National Excellence
American
Society for Quality Control
Institute
of Food Technologists
International
Association for Food Protection
Chapter 3: What
Is HACCP-Based Total Quality Management?
Total
Quality Management (Company Wide Quality Improvement)
Quality
Control, Quality Assurance, and Quality Improvement
Customer
Satisfaction
Total
Quality Management Cycle
Management
Process
Food
Processing Policies, Procedures, and Standards
Retail
Food Policies, Procedures, and Standards
The
Defect Prevention Process
Employee
Certification
Organization
for Total Quality Management
The
Problem-Cause-Removal-Prevention Process
Total
Quality Management Team
Problem
Solving Documentation
The
HITM 10-Step Total Quality Management Program
Fundamentals
for Achieving Quality-Assured Performance
Chapter 4: What
Is HACCP?
HACCP
(Hazard Analysis and Critical Control Points)
History
of HACCP
Terms
and Definitions Used in HACCP-Based Operations
Hazards
in the Food System
What
Documents Should be Used to Provide the Fundamental Guidance for a
HACCP Plan?
NACMCF
HACCP
NACMCF-Adapted
Generic 5-column HACCP Plan
Food
Operations Risk Management
Codex
Alimentarius HACCP
USDA
HACCP
FDA
Fisheries HACCP
FDA
Commercial Food Process HACCP
FDA
Retail HACCP Principles Guide
HITM
Retail Food HACCP-TQM
Food
Process Hazard Control Guidelines
Menu
HACCP Categorization with Examples
QA
Recipe Flow
Chicken
Cacciatore QA Recipe Flow
Quality-Assured
HACCP Recipe Procedures
HITM
Principles of HACCP
Concepts
Underlying HACCP
Questions
to Ask and Information to Gather When Doing a Hazard Identification
Safety-Assured Product Process Analysis
What
is Hazard Analysis?
HACCP
Assumes that the World is Always Contaminated
Foods
Associated with Foodborne Illness Incidents
What
Hazards Must Be Controlled?
What
Is a Critical Control?
HACCP,
A Pre-Control Process
Regulatory
Inspections
Critical
Control Points in the Sequence of Illness, Disease and Injury Causation
Summary
Chapter 5: The
System for HACCP-Based Food Safety Assurance
Safety: A
Part of Quality
Safety
Assurance
The
System for HACCP-Based Food Safety Assurance
Hazards
and Controls in Retail Foodservice, Market, Vending, and Home
Hazards
and Basic Controls in the Food Environment
Error-Cause-Prevention
Analysis for Foodservice Foodborne Illness Prevention
Foodborne
Illness Hazards and Control Policies, Procedures, and Standards for
Pasteurized-Chilled Food Systems
Development
of Motivated Employees to Error-Free Task Performance
Chapter 6:
Pathogenic Substances in Food
Reports
of Foodborne Outbreaks
Foodborne
Illness Factors
How to
Determine Whether a Food is Hazardous
Types
of Illness from a Control Viewpoint
Pasteurization
vs. Sterilization
Pathogenic
Substances in Food and Water
Estimated
Number of Foodborne Illness Cases
Major
Hazards Associated with Food Groups
Documented
Foodborne Outbreaks and Vehicles of Transmission
National
Research Council (NRC) List
Organisms
Grouped by Hazard Severity
Foodborne
Illness Thresholds and Quality Levels
Complications
Observed After Illness
Chapter 7:
Nutrition and Nutrition Retention
Dietary
goals
Dietary Guidelines, 2005
Nutritional
Labeling
Compliance
Thermal
Processing and Its Effect on Food
Optimizing
Nutrient Retention During Thermal Processing of Food
Time-Temperature
Sterilization
Stability
of Nutrients
Chapter 8:
Events that Lead to Foodborne Illness and Injury
Cause
Analysis
Factors
that Contribute to Foodborne Outbreaks
Events
Leading to Foodborne Illness in the United States, 1973-1982
Analysis
of the Factors that Cause Foodborne Illness and Injury
Components
of Food Hazard Analysis
Chapter 9:
Separating Process and Product Attributes and Variables Into Safety,
Regulatory, and Quality Attributes and Variables
Process
and Product Attributes and Variables:
The Key to QC, QA, and QI
Government
vs. Industry Control
Safety,
Regulatory, and Quality Attributes and Variables
Sensory
Evaluation of Food
Recipe
Attributes
Classes
of Defects
Control
Charts
Reacting
to Control Charts
Out of
Control Symbols
Chapter 10:
Sampling: To Determine the Performance
of the System
Normal
Contamination
Guidelines
and Standards
Finished
Product Sampling
Two-Class
Plan
Three-Class
Plan
Chapter 11:
Step By Step Flow Diagramming:
Analytical Description of a Process
System
Description
Flow Diagram
Step
Operations
Recipe
Process Flow Charting
Flow
Process Action Words
Step
Description
HACCP
Procedures Worksheet
Quality
Improvement
QA
(Quality-Assured) Recipe Flow
Quality-Assured
Recipe Procedures (QARP)
Barley
Soup QA Recipe Flow
Barley
Soup (QARP)
Cream
Celery Soup (QARP)
Beef
Stew (QARP)
Vegetable
Chowder
New
England Clam Chowder (standard recipe)
New
England Clam Chowder QA Recipe Flow
English
Beef Broth (standard recipe)
English
Beef Broth QA Recipe Flow
Chicken
Cacciatore (standard recipe)
Chicken
Cacciatore QA Recipe Flow
Chicken
Cacciatore (QARP)
Chapter 12:
Developing a Zero-Risk Process through Failure Mode and Effect Analysis
Hazard
(Quality) Control
Predictive
Hazard Evaluation and Risk Reduction
Risk
Equation
Risk
Control
Checklist
Behavioral
Change Program
Retail
Food Operation Food Hazard Control Checklist
Chapter 13:
Foreign Objects in Food
Foreign
Materials in Food
Classification
of Hard Foreign Objects in Food
Food
Defect Action Levels
Control
of Hard Foreign Objects in Foods
Loss
of Business
Legal
Impact
Chapter 14:
Toxic and Chemical Hazards and Controls
Toxic
Constituents of Plant Foodstuffs
Intentional
Additives
Incidental
Additives
Toxic
Containers
Effects
of Aluminum
Toxic
Metal Control / Backflow Prevention
Adverse
Reactions to Food
Allergic
Mechanism
Anaphylactic
Shock
Foods
Responsible for Allergic Reactions
Case
Histories
Medication
and Medical Treatment
Avoidance
is Best Control
Legal
Implications
Food
Labeling
How a
Retail Food Supplier Can Deal with This Problem
Chapter 15:
Temperature Measurement and Control
Types
of Temperature Measuring Devices
Calibration
Measuring
Temperatures of Food During Cooking to Verify Pasteurization
Measuring
Performance of Equipment
Measuring
Temperatures in a Container
Selected
Thermometer Specifications
Chapter 16: The
Microbiological Principles of Hazard Control
Hazard
Level
Microbiological
Factors
Foodborne
Illness Agents Grouped for Foodservice Control
Thermal
Destruction
Microbiological
Factors
Human
Sources of Pathogens
Food
Cooking Temperatures
Food
Pathogen Control Data
Food
Cooling Microbiology
Cooling
Standards
Refrigerated
Food Holding
Salmonella spp. Growth in Cooked Beef During Cooling
Slow
Cooking Roast Beef
Growth
and Survival of Clostridium perfringens
in Beef During Heating and Cooling
Chapter 17: Raw
Ingredient Hazards and Controls
Contaminated
Ingredients
Potential
Pathogens in Food
Shellfish
Hazards (Oyster, Clams, and Mussels)
Fish
Parasites (Roundworms, Tapeworms, and Flukes
Fish
Toxins and Poisons
Mushroom
Hazards
Pork
Egg
Hazard Analysis and Critical Controls
Chapter 18:
Hazard Control with Acids
Introduction
Government
Regulations for Commercial Production of Acidified Foods
Definitions
Other
Definitions (not in the regulations)
Products
That Are Not Acidified Foods
Definition
of pH
The
Relationship Between pH and Hydrogen Ion Concentration
Antimicrobial
Spectra of Organic Acids Used in Food
Data on the pKa,
Solubility, and the Use of Organic Acids and Esters as Food
Preservatives
Measuring
pH
Limits
of pH Allowing Growth of Various Microorganisms
Destructive
Activity of Weak Organic Acids
Salad
Dressing Characteristics
Salmonella Inhibition
Clostridium
botulinum
Inhibition
The
Use of Acid in Typical Classical Recipes
Shelf
Life of Dressings
Approximate
pH of Foods and Food Products
pH
Table
Chapter 19:
Water Activity - Application to HACCP
Definition
of Water Activity (aw)
Moisture
Sorption Curve
Water
Activity Growth Limits
Water
Activity of Foods
Solutes
Water
Activity in Frozen Foods
Effect
of Low Relative Humidity
Control
of Water Activity
Chapter 20:
Microbiological Growth
The
growth problem
Determining
Growth Rates
Calculating
Growth Rates
FDA
Food Code Recommendations
Adjusting
Calculations to the Cold Food Hold Guidelines
Range
of Temperatures for Growth of Foodborne Pathogens
Use of
Reported Generation Times for Predicting Growth of Pathogens
Generation
Times for Aerobic Bacteria in a Variety of Foods
Generation
Times for Listeria monocytogenes in a
Variety of Foods
Generation
Times for Staphylococcus aureus in a
Variety of Foods
Generation
Times for Salmonella spp. in a
Variety of Foods
Generation
Times for Yersinia enterocolitica in
a Variety of Foods
Generation
Times for Clostridium perfringens in
a Variety of Foods
Times
for Production of Toxin by Clostridium
botulinum in a Variety of Foods
Summary
of Generation Times of Pathogenic Bacteria in a Variety of Foods
Calculated
Rate of Multiplication of Various Bacteria in Food
Energy
of Activation
Low
Temperature Spoilage
Discussion
Conclusion
Microbiological
Multiplication Calculator
Chapter 21:
Microbial Inactivation
Microbial
Inactivation
Selecting
Microorganisms
The
Experimental Process for Determining Kill
Angelotti's
Experiments
Determination
of Upper Temperature Growth Limits
Determination
of Inactivation
Destruction
of Salmonella enteritidis
Calculating
Death Rates (Destruction Values)
USDA
and FDA Pasteurization Guidelines / Standards
Minimum
Process Time
Comparison
of Salmonella spp., Listeria monocytogenes,
and Escherichia coli O157:H7 D-values
Pork
Standards
Poultry
Standards
Milk
Pasteurization
Egg
Pasteurization
Pasteurization
Standards Summary
Compilation of Salmonella spp. D-values
Compilation of Staphylococcus
aureus D-values
Compilation
of Listeria monocytogenes D-values
Summary
Appendix
Survival
of Salmonella enteritidis in Food
Products Containing Raw Eggs
Chapter 22:
Calculating the Total Lethality of a Pasteurization Food Process
The
Concept of Total Lethality
Pasteurization
and Storage Stability of Hamburger Broth
A
Typical Pouch Cooking Curve
Total
Lethality Calculation
Food
Pasteurization Lethality Plot
Calculating
the Integrated Lethality of the Pasteurization Process
Kettle
Cooking
Chapter 23:
Food Cooling
Introduction
Thermal
Properties of Foods
Food
Geometry
Plotting
a Cooling Curve – "Standardized Cooling Plot Curve"
Cooling
Standards (USDA, FDA)
Cooling
as Influenced by Air Flow in Refrigeration Units, Tumble Chillers,
Containers
and Types of Shelving
Steps
for Calculating Refrigeration Capacity
Cooling
Progressively
Cooling
Times
Comparison
of Rapid Chilling, Rapid Blast Refrigeration, and Rapid Freezing Methods
Time
Temperature Relationships and Load in Refrigerator During Chilling
Turkey
Cooling
Sliced
Turkey Cooling
Water
Filled Kettle Cooling
Chilled
Water Bath Cooling
Food
Cooling (Simulated Gravy)
Effect
of Container on Cooling Rates
Effect
of Airflow and Evaporation on Cooling
Effect
of Stirring / Not Stirring
Blast
Chilling vs. Blast Freezing
Cooling
Methods -- 6 Hours to 41°F (5°C)
National
Sanitation Foundation Refrigerator and Freezer Standards
Refrigerator
Cooling Capacities
Blast
Cool Refrigeration
Cold
Pan Specification
Retail
Refrigeration Merchandisers
Summary
Chapter 24:
Personal Hygiene
Introduction
Humans
as a Source of Pathogens
Fingertip
and Hand Washing Must be Enforced by Management
Foodborne
Diseases of Human Origin
Microorganisms
on and in the Body
Importance
of Effective Hand Washing
Effective
Hand Washing
Comparison
of Hand Disinfectants and Unmedicated Hand Soaps and Detergents
Drying
Hands
Preventing
Contamination from Hands
Glove
Use
Personal
Hygiene Training
Hand
Infections and Bandages
Summary
A
Summary of Control Standards for Hand Washing and Personal Hygiene for
Food
Production and Foodservice Personnel
Chapter 25:
Cleaning and Sanitizing
Purpose
of Cleaning
Control
of Surface Microorganisms - Biofilms
Dry
Cleaning
Effective
Cleaning and Sanitizing
Types
of Soil
Cleaning
Agents (Soaps and Detergents)
Water
Cleaning
Systems
The
Four-Step Sanitizing Process
Sanitizers
Types
of Chemical Sanitizers
Concentration
Test Kits
Comparison
of Sanitizers
The
Surface Sanitizing Process
Equipment
Cleaning and Sanitation
Mechanical
Dishwashing - HACCP Principles
Floors
Checking
a Surface for Microorganisms
Microbiological
Sampling
Chapter 26:
Specification of the Process and Products (Recipe Development)
Goals
Product
Safety
Recipe
or Formulation Attributes
Chilled
Food Recipe Development
Factors
for Improved Quality Assurance and Shelf life Extension
Temperature
Shelf
life Testing
Specifying
the Maximum and Minimum Capacities of the Process
Labeling
Chapter 27: Ingredients
Ingredient
Quality Specifications
Ingredient
Microbial Specifications
Acid
Ingredients
Bacterial
Cultures as Microbial Antagonists
Water
Activity
Eh
(Oxidation-Reduction Potential)
Specified
Ingredients
Microbial
Antagonists
Chapter 28:
Food Thawing
Microbial
Growth During Food Thawing
Microbial
Growth During Thawing of Frozen Whole Eggs
Agitated
Water
Dielectric
Heat
Thawing
and Refreezing
Inactivation
of Microorganisms in Temperature-Abused Products
Illustration
of Approved FDA Methods
Chapter 29: The
Pasteurized-Chilled Food Processes
Introduction
Temperature
Guide
Recipe
Hazard Evaluation
Chilled
Foods
Spoilage
Freezing
Food Extends Shelf life -- Must be Thawed
Package-Pasteurize
vs. Pasteurize-Package
Seven
Recipe Processes
USDA-Specified
Chilled Food Processes
HACCP
Flows of Chilled Food Processes
Frozen
Products
Testing
a Recipe to Find Its Critical Failure Points
Hazard
Analysis and Control Guidelines for the Production of Chilled Foods
Chapter 30:
Heating Equipment
Three
Basic Types
Temperature
Measurement
Chapter 31: Hot
Holding HACCP
Preparing
Food Ahead of Planned Service and Inadequate Hot Holding
Examples
of Problems
Controls
Roast
Beef
Patient
Food Temperatures
Chapter 32:
Cooling Equipment
Four
Basic Types
Chapter 33:
Food Serving and Transport
Display,
Transport, Serve, Leftovers
Suggestions
for Holding Hot Food Hot and Cold Food Cold During Transport and Service
Chapter 34:
Facility and Environmental Quality Assurance:
A Basic Consideration in Facility Design
The
Kitchen as a Food System
Kitchen
Design and Food Handling Processes
Design
Analysis
Air
Gaps and Backflow Prevention
Construction
HACCP -- Facility Construction, Fixtures, Lighting, Waste Disposal, and
Cleaning
System
Receiving
HACCP -- Principles
Dry
Storage, Freezer and Refrigerators Storage HACCP -- Temperature, Air
Flow, and
Cleaning Requirements
Cold
Storage Requirements
Equipment
HACCP - Quality Assurance Design Performance
Kitchen
Design for Progressive Preparation and Service
Ice
Machines
Summary
of Kitchen Design for Progressive Preparation and Service
Other
Quality Assurance Kitchen Design Characteristics
Appendix
Initial
Foodservice License Evaluation
Purchasing
Standards
Quality-Assured
Recipe Procedures
Quality
Assurance Food Facility Design Checklist
Cleaning
and Sanitizing Schedule and Instructions
Examples
of Typical Equipment to be Cleaned
Detailed
Sanitation Procedures and Standards
Maintenance
Schedule and Instructions
Pest
Control Schedule and Instructions
Chapter 35:
Controlled/Modified Atmosphere Vacuum Packaging
Functional
Purpose of Packaging
Modified
Atmosphere Packaging (MAP)
Vacuum
Packaging
Simple
Closure Without Air Exclusion
Microbiological
Food Packaging Concerns
Chapter 36:
Packaging Equipment
Packaging
Terms and Materials
Packaging
Properties Important for Chilled Foods
Closures
Cost
Storing
Film and Packaging Materials
Checking
and Sealing
Identification
of Rejects
Clipping
Rejects
Heat
Seal Rejects
Film
Characteristics
Chapter 37: The
HACCP-Based TQM Development Process
Plan
Organize
Operate
and Exercise Self-Control
Inspect,
Measure, Analyze and Improve the System and Processes
Chapter 38: The
QA Office and Laboratory
Quality
Assurance Department Functions and Responsibilities
Chapter 39:
Policies, Procedures, and Standards Manuals
Documenting
a Process
Food
Processing Plant Policies Procedures and Standards
Retail
Food Operations Policies, Procedures, and Standards
Accountability
Reviewing
and Updating
Chapter 40:
Certifying a HACCP-Based Total Quality Management Program
Certification
Food
Operation Hazard Control Report
Food
Production and Processing System HACCP Checklist
Food
System Quality Assurance (QA) Certification Criteria
Food
System HACCP Evaluation Form
Chapter 41:
HACCP-Based Total Quality Management
Purpose
of An Industry-Focused Self-Control Program
The Employee -- The Ultimate Hazard
Controller
The
Role of the Regulatory Agency in a Industry HACCP-TQM Program
Correct Knowledge (Key Controls)
Control
Principles for a Food Operation Self-Control Program
Summary
Chapter 42:
Food Safety Commandments for HACCP-Based Safety and Quality-Assured,
Pasteurized-Chilled Food Systems
Chapter 43:
Summary
The
Situation Today
Problem
Prevention
Appendix A:
Conversion Charts
Temperatures
Volumes
and Weights
Appendix B:
HACCP-TQM Reference Sources
Books
Cookbooks
Publications from Professional
Organizations
Appendix C:
Materials and Equipment
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