CHAPTER 2: Quality vs. Government Regulations
Management: The Critical Factor in Quality
Total Quality Management
Government Regulations
Government Personnel Training
Regulating Quality
Regulating Safety and Fraud
ISO 9000 -- International Competition
ANSI / ASQC Standard
The Malcolm Baldrige Award (Examination categories, items
and point values)
American Society for Quality Control
Institute of Food Technologists
International Association of Milk, Food and Environmental
Sanitarians
CHAPTER 3: What Is Total Quality Management (TQM)?
Historical American Management Philosophy: "Use it or Throw
it Away"
Total Quality Management (Company Wide Quality Improvement)
The HACCP-Based TQM Process
Total Quality Management
Principles of TQM
Quality Control, Quality Assurance, and Quality Improvement
Customer Satisfaction
Total Quality Management Cycle
Management Process
The Defect Prevention Process
Employee Certification
Organization for Total Quality Management
The Problem-Cause-Removal-Prevention Process
Quality Management Team
Problem Solving Documentation Forms
Problem Solving Graphics
The HITM 10 Step Total Quality Management Program
Fundamental for Achieving Quality-Assured Performance
Effectiveness of the Safety Assurance System
Morbidity and Oversite Risk Tree (MORT)
CHAPTER 4: What Is Food Safety Hazard Control for Safety
Assurance?
Purpose
Terms Used in HACCP (Definitions)
History of HACCP
Government Approach to HACCP vs. Industry
Some Basic Components of HACCP System as Outlined by ICMSF
USDA HACCP Strategy
The Question of Government Food Safety Regulations
Federal Regulatory Agencies and their Jurisdiction
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 the World is Always Contaminated
Foods Associated with Foodborne Illness Incidents
What Hazards Must be Controlled?
HACCP Application as a Concept
Four Hazard Categories
What is a Critical Control?
HACCP, A Pre-Control Process
Personnel Responsibilities
Employee Illness
Food Temperatures
Progressive Cooking
Hot Food Holding Times
Adequate Refrigeration
Kitchen Construction
The Role of Sanitarians
Regulatory Agencies Must Keep Industry Performance Data
Industry Can Control Hazards
Hazard Control
Defect (Problem) Analysis
Industry Competitive Quality Standards
Critical Control Points in the Sequence of Illness, Disease
and Injury Causation
Prevention through Improved Knowledge
CHAPTER 5: The System for Hazard Control-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
Confirmed Foodborne Disease Outbreaks, Cases, and Deaths
Major Hazards Associated with Food Groups
Documented Foodborne Outbreaks and Vehicles of Transmission
National Research Council (NRC) List
Classification of Worldwide Meat-Borne and Poultry-Borne Microbial
Pathogens According to Modes of Transmission
Organisms Grouped by Hazard Severity
Infection and Toxin Producing Organisms, Grouped by Hazards
Foodborne Illness Thresholds and Quality Levels
Complications Observed After Illness
CHAPTER 7: Nutrition and Nutrition Retention
Dietary goals
Nutritional Labeling and Education Act (NLEA) of 1990
Thermal Processing and Its Effect on Food
General Characteristics of Three Thermal Processes Applied
to Foods
Optimizing Nutrient Retention During Thermal Processing of
Food
Time-Temperature Sterilization Curve
Stability of Nutrients
CHAPTER 8: Events that Lead to Foodborne Illness and
Injury
Cause Analysis
Percentages of Factors that Contributed to the Occurrence
of Foodborne Outbreaks in the United States, England, and Canada
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
Descriptive Terms for Sensory Evaluation of Food
Recipe Attributes
Classes of Defects
Control Charts
Process Control Chart
Reacting to Control Charts
Out of Control Symbols
Chapter 10: Sampling: To Determine the Performance of
the System
Normal Contamination
Some Microbiological Guidelines and Standards for Foods
Finished Product Sampling
Suggested Sampling Plans for Combinations of Degrees of Health
and Conditions of Use (i.e. the 15 cases)
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 Flow Charting
Flow Process Action Words
Step Description (Card)
HACCP Procedures Work Sheet
Quality Improvement
Quality Assured Recipe Flow
Quality Assured Recipe Procedures (QARP)
Barley Soup QA Recipe Flow
Barley Soup (QARP)
Celery Soup (QARP)
Beef Stew (QARP)
Vegetable Chowder
Chicken Cacciatore (standard recipe)
Chicken Cacciatore QA Recipe Flow
New England Clam Chowder (standard recipe)
New England Clam Chowder QA Recipe Flow
English Beef Broth (standard recipe)
English Beef Broth QA Recipe Flow
Chapter 12: Developing a Zero-Risk Process through Failure
Mode and Effect Analysis
Hazard (Quality) Control
Illness, Disease and Injury Causation
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 and Control
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
Monosodium Glutamate
Percent Free Glutamate Occurring Naturally in Food
Sulfites
Nitrites and Nitrates
Incidental Additives
Toxic Containers
Effect of Aluminum and Iron Utensils on Food
Aluminum Effect on the Body
Aluminum in Food
Toxic Metal Control
Carbonation Machine Backflow Prevention
Food Allergy
Different Types of Adverse Reactions
Allergic Mechanism
Anaphylactic Shock
Foods Responsible for Allergic Reactions
Common Allergenic Foods
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
Bimetallic Stem Thermometers
Thermistor Thermometers
Resistance Thermometers
Infrared Surface Temperature Thermometers
Thermocouples
Thermocouple Connections
Calibration Baths
Heater Blocks
Measuring Temperatures of Food During Cooking to Verify Pasteurization
Measuring Performance of Equipment
Measuring Temperatures in a Container
Multi-Function, Field-Calibrate Thermocouple Thermometer
Precise. Fast Response Thermocouple Thermometer
Hand-Held Data Logging Instrument
Chapter 16: The Microbiological Principles of Hazard
Control
Hazard Level
Microbiological Factors
Foodborne Illness Agents Grouped for Foodservice Control
Thermal Destruction (Acid, Water Activity, Effect of Fat)
Microbiological Factors
Lag and growth
Freezing
Competitive Exclusion
Human Sources of Pathogens
Food Cooking Temperatures
Temperatures Used to Cook Food and/or Indicate Doneness
Food Pathogen Control Data Summary
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
Beef (10 lb) Cooked Using Alto-Shaam Beef Rare Program
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
Infected Chickens
Destination Standards of Tolerance for Grade AA, Grade A,
and Grade B Eggs
Critical Controls (for using fresh, in-the-shell eggs
Chapter 18: Hazard Control with Acids
Introduction
Data on the pKa , Solubility, and the Use of Organic Acids and Esters
as Food Preservatives
Antimicrobial Spectra of Organic
Acids Used in Food
Titratable Acid
Measurement of pH and Acidity
Limits of pH Allowing Growth of
Various Microorganisms
Destructive Activity of Weak Acids
Salad Dressing Characteristics
The Use of Acid in Typical Classical
Recipes
Normal pH Ranges of Selected Foods
Chapter 19: Water Activity
-- Application to HACCP
Definition of Water Activity
Moisture Sorption Curve
Water Activity (aw )
Growth Limits
Water Activity of Food
Principal Groups of Food Based
on Water Activity
Solutes
Water Activity in Frozen Foods
Effect of Low Relative Humidity
Control of Water Activity
Chapter 20: Microbiological
Growth
The growth problem
Typical Raw Ingredient Retail Microbiological
Process Control
Determining Growth Rates
Typical Microbiological Growth
at Refrigeration Temperatures
Calculating Growth Rates
Typical Microbiological Growth
and Death Curve Calculations
Generation times for Pathogenic
Bacteria
Calculation of Microbial Growths
Range of Temperatures for Growth
of Foodborne Pathogens
Use of Reported Generation Times
for Predicting Growth of Pathogens
Generation Times Calculated for
FDA 1993 Code
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
Summary Comparison of Plotted Data
Values
Optimal Bacterial Growth Time-Temperatures
Energy of Activation
Low Temperature Spoilage
Reported Generation Times for
Some Psychrotrophs at 0 to 20°C
Safe Holding Time for Food at
Specified Temperatures
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)
Example
of D-Value Curve
Example
of Z Value Curve
USDA and FDA Pasteurization Guidelines
/ Standards
Beef and
Roast Beef Standards
Minimum
Process Time After Minimum Internal Temperature is Reached (seconds)
Comparison
of Salmonella spp., Listeria monocytogenes, and Escherichia
coli O157:H7 D-Values
Pork Standards
Poultry
Standards
Other
USDA Standards
Milk Pasteurization
Pasteurization
Times and Temperatures for Milk and Milk Products
Egg Pasteurization
Heat Resistance
of Salmonella in Egg Products
Egg Pasteurization
Chart
Pasteurization Standards Summary
Salmonella D-Values
Staphylococcus aureus D-Values
Comparison of Salmonella
spp., Staphylococcus aureus and Escherichia coli D-Values
Compilation of Listeria monocytogenes
D-Values
Summary
Food Pasteurization
Table
Chapter 21: 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
Times at Specified Temperatures
for 1D, 3D, and 7D Salmonella Inactivation
Pasteurization and Storage Stability
of Hamburger Broth
A Typical Pouch Cooking Curve (Vacuum
Packed Chicken Breast)
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 Curve in
a 35°F Refrigerator
Cooling Standards (USDA, FDA, UK)
USDA Cooling Guidelines
FDA Guidelines
Refrigerated Food Holding
Food Cooling Calculations
Steps for Calculating Refrigeration
Capacity
Food Cooling in a 38°F Refrigerator
Cooling Progressively
Cooling
Requirements for Mass ("X") of Food (Cp = 1)
Cooling Times
Comparison of Rapid Chilling, Rapid
Blast Refrigeration, and Rapid Freezing Methods
Times
to Cool 5- to 6-Pound Portions, 2 Inches Deep, to Indicated Core Temperatures
Time-Temperature Relationships
and Load in Refrigerator During Chilling
Effect
of Time on Temperature of Ground Beef During Chilling Process
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
List of Foodborne Diseases of
Human Origin, The Causal Agent of which is Shed in an Infective Form
Microorganisms on and in the Body
Resident
Microorganisms
Transient
Microorganisms
Importance of Effective Hand Washing
Comparison of Hand Disinfectants
and Unmedicated Hand Soaps and Detergents
Quantity of Soap
Detergency
or Lathering Ability
Skin Irritation
Contaminated
Bars of Soap
Liquid
Hand Soaps or Detergents
Choice
of Soap for Food Production Areas
Drying Hands
Gloves
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
Aerosol Contaminants
Effective Cleaning and Sanitizing
Types of Soil
Food Soil
Characteristics
Cleaning Agents (Soaps and Detergents)
Types of Detergents Available for
Food Process / Service Installations
Water
Cleaning Systems
The Four Step Sanitizing Process
Sanitizers
The Chambers Test
Types of Chemical Sanitizers
Chlorine
Compounds
Dilutions for Using Household Bleach as a Sanitizer
Iodine
Compounds
Quaternary
Ammonium Compounds
Acid-Anionic
Sanitizers
Concentration Test Kits
Test Kit
Problem
Oxidation-Reduction Potential
Comparison of Sanitizers
The Surface Sanitizing Process
Equipment Cleaning and Sanitation
Multiplication
of Microorganisms on Cutting Board Surface Incubated at 95° F
Mechanical Dishwashing -- HACCP
Principles
Floors
Checking a Surface for Microorganisms
PetrifilmTM Aerobic Count Plates Surface Sampling
Kit
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
Illustration of Approved FDA Methods
Chapter 29: The Pasteurized-Chilled
Food Processes
Introduction
Temperature Guide
Temperature Guide for Food Processing Procedures in Foodservice
Recipe Hazard Evaluation
Chilled Foods
Spoilage
Freezing Food Extends Shelf-Life
-- Must be Thawed
Package-Pasteurize vs. Pasteurize-Package
Seven Recipe Processes
Thick
Foods
Thin,
Raw Protein Items, Less Than Two Inches Thick
Stocks,
Sauces, Brews
Fruits,
Vegetables, Starches, Seeds, Nuts, and Fungi
Doughs,
Batters, and Pastries
Hot Combination
Dishes
Cold Combination
Dishes
USDA-Specified Chilled Food Processes
HACCP Flows -- 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
Types
Ovens
Water
Baths
Retort
Kettles
Swept
Surface Heat Exchanger
Temperature Measurement
Chapter 31: Hot Holding HACCP
Preparing Food Ahead of Planned
Service and Inadequate Hot Holding
Examples of Problems
Cooling
Rate of Food After Plating and Portioning
Controls
Temperature
of Roast Beef Held in a Winston Products Company 4-Pan Hot Food Merchandiser
Temperatures
for Serving Food to Patients
Chapter 32: Cooling Equipment
Types
Air Cooling
Walk-In Refrigeration Specifications
Vacuum Cooling
Water Bath
Plate-Metal Surface Heat Exchangers
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
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
Chapter 34: 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
Kitchen Sanitation Procedures and
Standards Sheet
Pest Control Schedule and Instructions
Maintenance Schedule
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
Heat Seal
Rejects
Film Characteristics
Chapter 37: The HACCP TQM
Development Process
Planning
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
Planning
Organization
and Training
Operating
and Controlling
Measuring
and Enforcing
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 (TQM)
Purpose of An Industry-Focused
Self-Control Program
The Role of the Regulatory Agency
in a Industry HACCP-TQM Program
Control Principles for a Food Operation
Self-Control Program
A City / State Master Plan for
Zero Food Industry Liability Costs
Chapter 42: Food Safety Commandments for HACCP-Based Safety and Quality Assurance Pasteurized-Chilled Food Systems
Chapter 43: Summary
Appendix A: Temperature Conversion Chart; Volumes and Weights Conversion Charts
Appendix B: HACCP Books
Appendix C: Materials and Equipment