HACCP

25 July 2022
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Active Managerial Control
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preventative rather than reactive approach to food safety. Procedures to prevent, eliminate, or reduce foodborne illness risk factors through continuous system of monitoring and verification.
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Foodborne Illness Risk Factors include:
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Food from unsafe sources, Inadequate Cooking, Improper Holding Temperatures, Contaminated Equipment, Poor Personal Hygiene.
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HACCP - what does it stand for
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Hazard analysis and critical control point
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Active managerial control through HACCP principles is achieved by:
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Identifying the food safety hazards attributes to products, determining the necessary steps that will control the identified hazards, and implementing on-going practices or procedures that will ensure safe food.
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HACCP voluntary or involuntary?
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Food Code requires HACCP plan when doing specialized processes like reduced oxygen packaging. In general though the implementation of HACCP at the retail level is voluntary. FDS endorses voluntary implementation as effective means for controlling foodborne illness risk factors.
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HACCP may offer what addition advantages
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Reduction in product loss, increase in product quality, better control of product inventory, consistency in product preparation, increase in profit, increase in employee awareness and participation in food safety.
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Federal performance standards
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define safety expectations for specific foods, saying the number of disease causing microorganisms that need to be destroyed through a process. For example, instead of cooking chicken to 165 for 15 seconds like the Food Code says, performance standards allow you to use a different combo of time and temp as long as same level of public safety is achieved.
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When using performance standards you must have
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a comprehensive HACCP plan approved by regulatory authority and recores in support of plan must be kept.
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HACCP has no single correct application
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variations are appropriate as long as based on sound public health judgment.
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The goal in applying HACCP principles in retail and food service is to have
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to have you, the operator, take purposeful actions to ensure safe food.
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What year and company was HACCP first used
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...1960s by the Pillsbury Company to produce the best food for astronauts.
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What are hazards?
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biological, physical, or chemical properties that may cause food to be unsafe for human consumption.
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Biological hazard examples
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bacteria and their toxins, parasites, viruses.
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Physical hazard examples
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Bandages, jewelry, stones, glass, etc.
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Chemical hazard examples
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natural plant and animal toxins, unlabeled allergens, nonfood grade lubricants, cleaning compounds, food additives, insecticides.
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Basic prerequisite programs should be in place to:
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1.Protect products from contamination, 2. control bacterial growth that can result from temperature abuse, 3. maintain equipment.
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Before HACCP system to be effective you need a strong foundation based on prerequisite programs. These include things like
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facility design, supplier control, ingredient specifications, equipment design, cleaning and sanitation, personal hygiene, employee training, pest control, receiving, storing, and shipping procedures.
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Prerequisite Programs to Control Contamination insures that
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1. soiled/unsanitized surfaces do not contact food 2. workers with vomiting or diarrhea are restricted/excluded 3. raw animal food doesn't contaminate cooked food 4. effective handwashing 5. eating, smoking, drinking in food prep areas prohibited 6. water used is potable 7. toxic compounds are labeled, stored, and safely used. 8. Contaminants (pesticides, cleaning compounds etc) don't con't any food 9. Food, packing, and food contact surfaces not contaminated by physical hazards like broken glass, jewelry, etc. 10. Effective pest control system is in place. 11. hair restraints are used and clean clothing is worn. 12. wearing of jewelry other than wedding ring is prohibited.
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Prerequisite Programs to Control Bacterial Growth ensure that
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potentially hazardous food is received and stored at a refrigerated temperature of 41 F / 5 C or below.
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Prerequisite Programs to Maintain Equipment ensure that
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1. food contact surfaces including utensils are cleaned/sanitized 2. tempurature devices calibrated regularly 3. cooking and hot holding equipment are routinely checked 4. cold holding and cool equipment routinely checked 5. warewashing equipment is operated according to manufacturer's specifications 6. toilet facilities are accessible to employees and maintanied
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There should be SOPs (standard operating procedures) related to each of prereq programs. The SOP's will describe:
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What tasks are to be done, who will complete the tasks, standards that must be met, and how the completion of the task will be documented.
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7 HACCP Principles
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1.Conduct Hazard Analysis 2. Decide on the Critical Control Points (CCP's) 3. Determine the Critical Limits 4. Establish Procedures to Monitor CCPs 5. Develop Corrective Actions 6. Establish Verification Procedures 7. Establish a Record Keeping System
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HACCP Principle 1: Conduct Hazard Analysis -
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Understanding the operation and determining what food safety hazards are likely to occur.
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HACCP Principle 2: Decide on Critical Control Points -
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Once the control measures in principle 1 are determined, it's necessary to identify which of the control measures are absolutely essential to ensuring safe food. A CCP is an operational step where control can be applied and is essential for ensuring that a food safety hazard is eliminated, prevented, or reduced to an acceptable level. If a later step in the same process that will eliminate/reduct the hazard then the former step is not a CCP. Not all steps are CCPs. Only the ones that are absolutely essential to food safety are CCPs.
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HACCP Principle 3: Determine the Critical Limits-
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Each CCP needs boundaries that define safety. Critical limits are parameters that must be achieved to control a food safety hazards. For example for cooking pork chops the critical limit is 145 degrees for 15 seconds. Critical limits are MEASURABLE and OBSERVABLE.
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HACCP Principle 4: Establish Procedures to Monitor CCPs-
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Monitoring involves making direct observations or measurements to see that the CCPs are kept under control be adhering to the established critical limits. Basically someone has to keep track of the CCP.
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HACCP Principle 5: Develop Corrective Actions -
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Occasionally the process or procedure will fail to meet the established critical limits. This step establishes a plan for what happens when a critical limit wasn't met at a critical control point. Operator decides what will happen in that event, communicates those actions to the employees, and trains them in making right decisions.
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HACCP Principle 6: Establish Verification Procedures -
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This principle is about making sure that the system is scientifically sound to effectively control teh hazards. This step additionally ensures that the system is operating according to what the specified plan. Like calibrating equipment, observing employees, etc. See if anything needs to be modified or improved.
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HACCP Principle 7: Establish Record Keeping System -
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The HACCP plan itself and any monitoring, corrective action, or calibration records produced in the operation of HACCP system. Should be as simple as possible so employees will have time to keep records up to date.
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HACCP was originally developed for food manufacturing plants so it can be difficult to apply these same principles in retail and food service establishments. What sets retail apart from most food processors?
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High employee turnover, so food safety training must be continuously provided. Low profit margin and less capital to work with. There is an almost endless number of production techniques, products, menu items, etc that are not easily adapted to a simple, standardized approach.
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Process Approach to HACCP
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Dividing the many food flows in an establishment into broad categories based on activities or stages in the preparation of the food, then analyzing the hazards, and placing managerial controls on each grouping.
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Food preparation process
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Path that food flows from receiving through sale to the consumer. Receiving, storing, preparing, cooking, cooling, reheating, holding, packaging, serving, selling etc.
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Most food items produced in a retail or food service establishment can be categorized into one of three preparation processes based on the number of times the food passes through temperature danger zone (41 to 135).
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Process 1: Food Preparation with No Cook Step (no cook step in destroying the pathogens) Process 2: Preparation for Same Day Service (one trip through temperature danger zone.) Process 3: Complex Food Preparation (2 or more complete trips, like cooking, cooling, reheating, etc).
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For food preparation process it is important to remember:
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that even though variations of the three food prep process flows are common, the control measures to be implemented in each process will generally be the same based on the number of time food goes through the danger zone.
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Even though variations in foods and in three food prep process flows are common, the control measures will generally be teh same based on
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the number of times the food goes through the tempurature danger zone.
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All of the following control measures should be implemented regardless of the food preparation process used
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No bare hand contact with ready to eat foods, proper hand washing, restriction or exclusion of ill employees, prevention of cross contamination.
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Food Preparation Process 1 - Food Prep with No Cook Step
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Example Flow: Recieve, store, prepare, hold, serve. Raw ready to eat food like sushi, food cooked at processing level but not at retail level, like deli meat, are in this category.
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For food prep process 1 should focus on having active control over the following:
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Cold holding, food source (especially for shellfish), receiving temperatures, date marking, freezing (certain species of fish intended for raw consumption) and cooling.
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Food Preparation Process 2 - Preparation for Same Day Service
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Example Flow: Receive, store, prepare, cook, hold, serve.Food is usually cooked and held and until serving, but can also be served immediately.
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For food prep process 2 should focus on having active control over the following:
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Cooking to destroy bacteria and parasites, and hot holding or using time alone to prevent the outgrowth of spore forming bacteria.
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Food Preparation process 3 - Complex Food Preparation
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Example Flow: Receive, store, prepare, cook, cool, reheat, hot hold, serve. This is foods usually prepared in large volumes or in advance for next day service.
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For food prep process 3 should focus on having active control over the following:
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Cooking to destroy bacteria and parasites, cooling to prevent outgrowth of bacteria, hot and cold holding or using time limits to control bacteria, date marking of ready to eat held more than 24 hours, reheating for hot holding if applicable.