SECTION XI

SELF-INSPECTION, CONTINUOUS QUALITY IMPROVEMENT

A. Product process monitoring / sampling plan
B. Daily self-inspection
C. Retail food operation food hazard control checklist
D. Receiving report
E. Calibration verification form

A.  Product Process Monitoring / Sampling Plan (Section XI, encl. 1).  Testing procedures for the microbiological quality of food and food contact surfaces should be established and records maintained.   Testing can be done in-house by the QC department for APC / spoilage counts.  Pathogens should be tested by an outside laboratory.
        Basic microbiological standards are:
             1. Excellent:  less than 1,000 SPC/gram
             2. Good:  less than 100,000 SPC/gram
             3. Marginal:  100,000 to 10,000,000 SPC/gram
             4. Unacceptable:  more than 10,000,000 SPC/gram
        On a food contact surface - less than 100 SPC / 8 square inches (50 square cm) is considered excellent.
        The presence of foreign objects in food must be monitored, and the incidence must be recorded.
        Chemicals in foods should not be a problem if food chemicals are measured carefully, and if cleaning and sanitation chemicals are stored properly.

B.  Daily Self-inspection (Section XI, encl. 2).  By knowing the hazards involved in the production and retailing of food products, producers can design their own self-control programs that can be used by both management and employees to produce safe, designated quality food products.
        All units are subject to federal, state, county, and municipal regulations, and are inspected by officials from one or more of these governmental agencies.  Inspection forms used by these agencies will vary, but the basic points are usually similar.  Food safety, namely, procedures that minimize the potential for foodborne illness, are of primary concern.  Food protection, personnel responsibilities, food equipment, utensil use, and good safety procedures must be observed.  Structure and utilities must be checked.  Detailed operation management and inspection standards should be written and available for review by regulatory agencies.  These standards must be itemized in a detailed checklist.

C.  The Retail Food Operation Food Hazard Control Checklist (Section XI, encl. 3).  Complete self-inspection forms combine government and HACCP requirements.  The Retail Food Operation Food Hazard Control Checklist is an example of a more complete foodservice inspection form that can be used to meet regulatory as well as quality standards.

D.  Receiving Report (Section XI, encl. 4). This form can be used to monitor and record the temperature and quality of incoming fresh produce, meat, and frozen supplies.

E.  Calibration Verification Form (Section XI, encl. 5).  Equipment must function correctly.  This form can be used to monitor equipment calibration on a regularly scheduled basis.


Encl. 1
PRODUCT PROCESS MONITORING / SAMPLING PLAN

Microbiological Testing for Food Products


Food Item
Microbial Test
Sample Size
Time Sample is Taken
TargetAmount
Critical Limit
Potato Salad SPC   1 oz.  10:00 a.m.  Less than 1,000/gram  100,000/gram

Microbiological Testing of Production Plant Surfaces

Food Item
Microbial Test
Sample Size
Time Sample is Taken
TargetAmount
Critical Limit

Presence of Particulate Matter

Food Item
Microbial Test
Sample Size
Time Sample is Taken
TargetAmount
Critical Limit

Presence of Chemicals / Toxic Compounds / Allergens

Food Item
Microbial Test
Sample Size
Time Sample is Taken
TargetAmount
Critical Limit


Encl. 2
DAILY SELF-INSPECTION OF CRITICAL CONTROLS

Date ________________________ Verified by _______________________________________


Item
Monitoring
Who
When 
Observation / 
Monitoring Person / 
Temp / Dates* 
Corrective Action
1. Description of problem and how eliminated
2. Proof that CCP is under control after fixed
3. Measures to prevent recurrence
4. Measures to control adulterated product
System 


Environment, facilities, equipment
Area clean, equipment clean and working; pest control 
Personal hygiene, hand washing
Sinks stocked, employees observed 
Training
Emergency plan 
Supplier certification 
Chemicals controlled 
Customer / employee feedback 
Inventory


Ingredients and products; rotated and dated; temperature; dry
Receiving


Trucks, authorized suppliers, condition; monitoring
Production


Within capacity; dated, rotated
Product flow, no cross-contamination
Recipes followed:  temperatures, ingredients
Transport, Service, Leftovers


Hot and cold food, holding and turnover
Cooling
Customer communication
Leftovers:  date, used

* Employee doing task; Temperature of food, equipment, air temperature; Expiration dates; Leftovers; Product turnover


Encl. 3
RETAIL FOOD OPERATIONS FOOD HAZARD CONTROL CHECKLIST
[41 to 140°F (5 to 60°C)]


Food Hazard Control Requirements
 Evaluation
MANAGEMENT
Maintains written policies, procedures, and standards for training and guiding all employees in the preparation and service of food.
Competent management level personnel [person(s) in charge] are trained in foodborne illness and disease prevention.  They lead the HACCP team and facilitate continuous improvement.
Organization chart and job duties sheets specify hazard control duties and responsibilities of all personnel.
Effective HACCP self-inspection is completed weekly; results are recorded and used for improvement.
Employees are trained and certified in safe food handling and receive regular training for improvement.
Management allocates adequate funds for the HACCP self-control program.
Management sets the example by strictly following all policies, procedures, and standards.
Correct performance of employees is enforced and rewarded.
Equipment and facilities provided allows the production of safe, high-quality products.
Documented procedures are in force for handling probable emergencies.
First aid supplies are adequate, appropriately stored, and available.
Customer comment cards and feedback are used to enhance quality.
License is conspicuously posted.
Smoking / no smoking regulations are enforced.
Truth in menu and advertising is practiced.
PERSONNEL 
Employees control food safety by using safe food handling methods and practicing good personal hygiene.
All personnel who prepare or serve food wash their hands using the:
Double wash method (2x): at the beginning of work; when entering the kitchen or production area; after using the toilet; touching vomit, fecal material, or any body fluids; after encountering any possible pathogenic conditions.
Single wash method (1x): after breaks, handling garbage and/or dirty dishes, blowing nose, touching soiled surfaces, and between handling raw and cooked / prepared foods.
Management is alert to ill employees and takes action by giving these individuals a non-food handling job or by sending them home.
 When employees wear disposable, plastic gloves for preparing and serving food, they wash their hands before putting gloves on and after removal.
Disposable gloves are changed and discarded each time a different contaminated object or surface is touched.
Employees who must wear heavy-duty gloves to protect their hands from harsh chemicals, detergents, or other irritants have their own personal pair of gloves.
Hand cuts and abrasions are washed and covered with a bandage and proper fitting plastic gloves.
Personnel wear properly fitting plastic gloves before touching blood or body fluids of another person.
Handkerchiefs and nose tissues are not carried in food production area.  Disposable tissues are used at hand washing sink.
No personal medication is allowed in the food production and food service areas.
Personnel do not eat, chew gum, or smoke while preparing and handling food.  (Personnel can drink from a closed, spill-proof container when working in a hot work environment, and dehydration is a problem.)
Personnel use utensils, plastic gloves, or paper sheets to handle food being served in the presence of customers.
Personnel do not touch food contact surfaces of glassware, dishware, flatware, and serving utensils.
Personnel do not wear jewelry other than plain wedding bands and avoid carrying or wearing any objects that might fall into food.
No unauthorized persons are allowed in food production and utensil-washing areas.
ENVIRONMENT
The area around the facility, including waste storage, is cleaned and maintained on a adequately scheduled basis.
Water used meets EPA (Environmental Protection Agency) water quality standards. 
Unit complies with local clean indoor air act or smoking / no smoking policy.
Sewage systems are maintained to meet established plumbing codes.
Poisonous or toxic materials (soaps, sanitizers, pesticides) are used in accordance with manufacturer's recommendations and are stored away from food production area.
Pest control program is followed.
FACILITIES
Facility design is approved by the health department.
Ventilation system is clean, maintained, and working correctly.
All garbage containers (inside and outside) are covered, durable, cleaned, and sanitized on schedule.
There is adequate provision for recycling.
Floors, walls, and ceilings are cleaned and maintained on a regular basis.
Laundry and laundry facilities are separate from food preparation area; area is clean, organized, and maintained. 
Separate sinks are available for hand washing, food washing, and utility (cleaning) purposes, and are used only for these purposes.
Restrooms, break rooms, and locker rooms are cleaned daily and always supplied with materials necessary for good employee hygiene.
EQUIPMENT
Equipment construction and equipment surfaces meet regulatory standards.
Adequate hot holding and cold holding devices are available and are calibrated to maintain foods at correct temperatures during storage, preparation, transport, and service.
Dunnage racks, shelving, pallets, dollies, etc. are made of correct materials and designed to store food at least 6 inches above floor.
All equipment is cleaned, sanitized, and maintained on schedule.
All items of equipment not necessary for operation of facility are stored or removed from premises.  Items needing repair are fixed within 15 days.
Appropriately identified sanitizer of proper concentration is available at all work stations and is used correctly.
Food preparers use food-temperature-measuring devices appropriately.
Equipment thermostats are checked and calibrated regularly.
Equipment has appropriate backflow prevention, including CO2 backflow prevention.
Refrigeration units have adequate cooling and air circulation capacity for amount of food to be cooled.
Refrigeration units and freezers are cleaned and maintained on schedule.
Refrigeration and freezer unit compressors are kept free of dirt.
Drainage lines from beverage dispensers do not run through potable ice bins.
Ice is dispensed with a plastic or metal ice scoop that is stored in a holder in the upper part of the ice compartment.  Ice is not scooped with a glass.
Hand sinks contain fingernail brush, soap, and single-use towels, and operate with a flow of 1 to 2 gallons of water per minute at 75 to 110°F within 3 seconds after turn-on.
2-compartment food sinks are used only for food preparation; are cleaned and sanitized regularly.
3-compartment sinks for pots and pans are adequate to get items cleaned, rinsed, sanitized, and dried.
The five-step cleaning process is used on cutting boards and all food contact surfaces.
Ware washing and pot washing equipment is maintained regularly and operated with correct water temperatures, pressure, detergent, and chemical sanitizer. 
Utility sinks are used for cleaning and disposal of cleaning solutions.
Detergents and sanitizers are used correctly for specified tasks; are stored correctly; are changed when the solutions are dirty and/or when concentration is inadequate.
Hot water supply is never <140°F (60°C).  [Exception:  water used for hand washing is 75 to 110°F (23.9 to 43°C).]
Hot water or steam, if used for sanitizing in a 3rd compartment sink  is >171°F for 30 seconds.
Clean glasses, cups, and other utensils will be stored covered or in an inverted position, and at least 6 inches above the floor in a clean, dry location.
Cracked, chipped, or broken glassware, dishware, flatware, and serving utensils are discarded.
Brushes are used correctly and are cleaned and sanitized daily.
Cleaning equipment (mops, buckets, pressurized equipment) is stored properly, away from food, clean equipment, or linen.
SUPPLIES AND MATERIALS 
Food supplies are purchased, whenever possible, from suppliers with HACCP-based Total Quality Assurance programs who provide information of probable levels of pathogen contamination in the food.
Any meat or seafood products that are served raw or partially cooked must be obtained from suppliers who certify a safe pathogen level for their products.
Food obtained from suppliers who provide no data is assumed to contain pathogenic microorganisms at hazardous levels and is stored and prepared in a manner that will reduce pathogenic microorganisms to a safe level.
All milk and dairy products served and used in preparation of products meet government pasteurization standards and are served safely.
Suppliers of chemical products provide material safety data sheets.
Suppliers of food containers and equipment provide information concerning composition of surfaces and provide instructions for use, cleaning, and maintenance. 
Recipes for all food production items are HACCP'd to include times and temperatures for all food handling steps in order to control process hazards. 
All deliveries are inspected upon receipt; substandard items that can cause disgust, alarm, or injury to consumers are rejected or returned.
Containers and packing materials are discarded promptly and properly.
Shelf-stable and frozen food items are stored properly and at correct temperatures.
Food is stored in non-corrosive, food grade containers, covered, labeled and "use-by" dated.
Refrigerated food items (including leftovers) are stored at <30°F, or for times and at temperatures that control the growth of pathogens to less than 10 generations.
All ingredients used in the preparation of products are inspected and recorded and discarded if quality or safety is questioned.
Raw and cooked foods are kept separate; any equipment that is used to prepare raw food is cleaned and sanitized before it is used to prepare any other products.
All raw fruits and vegetables are double-washed thoroughly in cold, flowing water and drained.
Work stations are cleaned about every 4 hours (surfaces <100 microorganisms / 8 sq. in.).
The five-step cleaning and sanitizing process is used on all food contact surfaces at least every 4 hours or between each change from contaminated food and clean pasteurized food (surfaces <100 microorganisms / 8 sq. in.).
Cleaning cloths do not cross-contaminate surfaces; sponges and metal scrubbies are not used.
Raw food temperature is maintained <41ºF during storage and <50ºF during pre-preparation and is not prepared more than 24 hours in advance of use.
Food is thawed by acceptable methods that control the growth of Listeria monocytogenes to <1 generation of multiplication.
Food chemicals are used according to regulatory and food facility guidelines.
All cooked food is considered to be potentially hazardous, unless it has a pH of <4.6,  aw <0.86, or is commercially sterilized in a sealed container.
Pathogen growth in Hollandaise, Béarnaise, and other cold sauces and salad dressings is controlled by addition of sufficient amount of acid ingredients to maintain the pH below 4.1, along with time or temperature to inactivate vegetative pathogens.
Food is heated from <50  to >130°F in <6 hours.  Raw meat, poultry, and fish are heated for sufficient periods of time to assure that the center temperature reaches a pasteurization temperature necessary to reduce Salmonella from 10,000,000:1.
When raw meat, fish, and poultry are cooked by microwaving, they are covered and heated until all parts of the food reach a temperature of 165°F.  The products are then allowed to stand covered for 2 minutes.
After cooking-pasteurization, all food products will be maintained >130°F (140°F - FDA recommendation) or cooled to <45°F within 15 hours (<41°F, <6 hours - FDA recommendation), or held for a time-temperature that controls pathogenic bacterial growth to <10 generations multiplication, after which products are discarded.
For quality, food is held hot for service for < 30 minutes.  Progressive food preparation is used whenever possible to retain high sensory and nutrient quality.
Hot combination dishes (casseroles, stews, thick soups) composed of pre-cooked ingredients must reach a center temperature of 165°F for >1 second within 2 hours (for quality), and within 6 hours for safety.
Cold combination items (salads and sandwich spreads) are prepared with ingredients cooled to <41°F; ingredients are combined and maintained at or <50°F during mixing, then returned to a 41ºF environment and used in <7 days.
Leftover food is not combined with fresh food.  It is only recycled once in another menu item.
Frozen dessert items are maintained at 0 to 30°F.
Unwrapped and potentially hazardous food is discarded after it has been served once.  Non-hazardous food that is still packaged and in sound condition may be re-served.
Serving utensils in use are kept >130°F, dry, or in a way that controls the multiplication of pathogenic bacteria to <10 generations.
Service stations are clean, orderly, and free from debris and spilled food.
Raw, potentially hazardous foods and pasteurized/clean foods are kept separate during service.
Soiled customer areas, tables, and counters are cleared promptly and cleaned with detergent and rinsed after each use; surfaces are sanitized at least every 4 hours.
All beverage dispensing equipment is maintained, cleaned and sanitized regularly.
Milk dispensing tubes are not longer than 3/4 inch and are cut at a 45° angle.  The plastic sleeve is removed.
Tableware and flatware (both multiple use and single service) are dispensed in a sanitary manner so that surfaces are protected from contamination.
Packaged food is not stored in undrained ice.
Ice meets Environmental Protection Agency water standards.
CONSUMER
Customers are not allowed to re-use any table or flatware when obtaining additional food from salad bars or buffet lines.
Customers are given safe handling information for all take-out food items.
To prevent possible allergic reactions, consumers are informed of ingredients in food if they request this information.
Any food returned by a customer is never re-used, re-served or sold.
There is surveillance to prevent customers from touching food directly with fingers or sabotaging food products.


Encl. 4
RECEIVING REPORT
Incoming Product Temperature / Visual Check

This form is used to check in fresh and frozen ingredients.  It is also used to record rejected food and reasons for rejection.
 

Date
Item & Lot #
Temperature
Comment


Encl. 5
CALIBRATION VERIFICATION FORM
Quality Control Department
Unit
Date
Reading of Item
Deficiencies and Corrective Action
Initials
Verification

District Merchandiser will verify the calibration of equipment when visiting the stores, at least on a monthly basis.


To Table of Contents
To Section X
To Section XII