HACCP-Based Specialized Processes For Retail Food

HACCP-Based Specialized Processesfor Retail FoodPresented byPamela Ross-Kung, MS, RSPresidentSeptember 12, 20191

GoalThe overall goal of this presentation is to provide anincreased awareness of specialized processes at retailfood establishments that require a HACCP plan so theycan be identified and brought into compliance withcurrent regulations.2

Objectives Identify specialized processes that require a HACCP plan under105 CMR 590.000: State Sanitary Code Chapter X: MinimumSanitation Standards for Food Establishments Recognize if a retail food establishment is conducting one ormore specialized processes during an inspection Determine regulatory action to be taken if a retail establishmentis conducting one or more specialized processes without priorapproval and/or a HACCP plan3

Specialized Processes Requiring a HACCP PlanA HACCP plan is required for all specialized processes Smoking* food as a method of food preservation rather than as a method of flavorenhancement PfCuring* foodPfUsing food additives or adding components such as vinegar (i.e. sushi, fermentation):Pf(1) As a method of food preservation rather than as a method of flavor enhancement(2) To render a food so that it is not a time/temperature control for safety food (TCS)Packaging TCS food using a reduced oxygen packaging method (ROP)Operating a molluscan shellfish life-support system display tank used to store or displayshellfish that are offered for human consumption (must obtain additional variance forwet storage systems from DPH (105 CMR 500.021(D)) PfCustom processing animals that are for personal use as food and not for sale or servicein a food establishment PfSprouting seeds or beansPfPreparing food by another method that is determined by regulatory authority to requirea variance (such as drying*, which could render the food shelf stable)Pf*We will often see overlap in these processes curing/drying/smoking, curing/smoking, etc.4

Processes Requiring a HACCP PlanProcessVarianceRequiredHACCP PlanRequiredVarianceExceptionHACCP PlanExceptionSmoking to preserve food or extend shelf lifeYESYESSmoking for flavorenhancement, color,or part of the cookingprocessSmoking for flavorenhancement, color,or part of the cookingprocessCuringYESYESAdding food additives or components torender food non-TCS or extend shelf life(i.e. acidification, fermentation)YESYESOperating Live Molluscan Shellfish SystemYESYESCustom Animal ced Oxygen Packaging (ROP)Other Methods (like drying)Methods under 3502.12 with validatedprocess5

HACCP Plan – No Variance(1) TCS food that is packaged using ROP method, maintained at41 F or less anHas a water activity of .91 or less;Has a pH of 4.6 or less;Is a meat or poultry product cured at a food processing plant;regulated by the USDA; orIs a food with a high level of competing organisms6

HACCP Plan – No Variance(2) Fish that is frozen before, during, and after packaging using aROP method (3-502-11)(3) Food that is prepared and packaged using a cook-chill orsous vide method (3-502-11)(4) Specific cheeses that are packaged using a ROP method(3-502-11)(5) Juice packaged in a food establishment without a warninglabel (3-404.11)(6) Unpackaged juice prepared in a food establishment serving ahighly susceptible population (3-801.11)7

Determining if the establishment isconducting a specialized process Start by reviewing the menu Look at the obvious equipment Look for signs of specialized processes in:refrigerator(s)freezer(s)storage areasareas they seem hesitant to show youareas they say are not under their control8

Menu AssessmentAsk specific questions: What foods do you make from scratch (prepared on premise)?Do you use any special ingredients or equipment?Do you have any seasonal items?Do you bring in any foods made at your home, or atanother location? Do you conduct any specialized processes? (Have your list ready)Note: You have the right to ask for invoices if you are not sure wherea product, or an ingredient originated. You also have a right toask to see a recipe to verify ingredients.9

Sample Menu ItemsLomo Margherita (cure)Cured Pork Loin, San Marzano Tomatoes, Fresh Mozzarella, BasilPastrami (cure)Swiss, Deli Mustard, Sauerkraut (fermented)AndouilleSmoked Sausage (cure)Little SmokiesSmoked Sausage (cure)Mango Lassi (homemade yogurt - fermentation)Cured Egg Yolks (additives – no curing salts)10

Recognizing Signs ofSpecialized Processing11

SMOKING12

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SmokerPhoto: MASTERBUILT14

This smoker can be mistakenfor a BBQ ovenPhoto: Home Depot15

Smoking or DryingOvenCheck for certification symbol(NSF, ANSI, ETL, UL, etc.)16

CURING17

Pink Salt18

BaconROP & CurePhoto: VacMaster19

Bacon Curing20Photos: The Sausage Maker

Brine Injector NeedlesPhoto: PreMIala21

Smoking and/orCuring22

DRYING23

Drying/Curing KIT24Photo credit: Ask The Meatcutter

Casing Kit25

Beef JerkyStart of process26

Beef JerkyEnd of process27

Dryingand/orCuring28

Beef Jerky29

DehydratorCheck for certification symbol(NSF, ANSI, ETL, UL, etc.)30

DehydratorCommercial drying oven31

Drying CabinetCheck for certification symbol(NSF, ANSI, ETL, UL, etc.)32

Drying or SmokingOvenCheck for certification symbol(NSF, ANSI, ETL, UL, etc.)33

REDUCED OXYGENPACKAGING (ROP)Cook-chill / Sous Vide34

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Sous videPhoto - Plascon USA38

Cook-Chill orSous vide39Photo - Plascon USA

Cook ChillIce BathPhoto - Plascon USA40

VacuumPackagingMachinesTabletop and floor model41

ROPVacuum packagingmachine stored so it’snot obvious42

ROPSmall heat sealer43

Immersion Circulator& BathPhoto: Web Restaurant44

Photo: Web Restaurant45

ImmersionCirculatorCalibration test46Photo - Polyscience

Blast Chillers47Photos – Web Restaurant

FOODADDITIVES48

SushiAcidification49

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KombuchaFermentation52

Kombucha53

Yogurt Maker andStarter CultureFermentation54

Large FermentingBucketCan make up to 15 gallons55

YogurtFermenting in a warmplace56

KIMCHIFinished product57

SAUERKRAUT58

LIVEMOLLUSCANSHELLFISHLIFE-SUPPORTSYSTEM59

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Don’t just lookfor typical“TANKS”61

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CUSTOMANIMALPROCESSING63

Deer MeatPhoto credit: Brady Miller64

Photo credit: Brady Miller65

Photo credit: Dan Wilde66

Photo credit: Brady Miller67

CUSTOMPROCESSINGUnsafe practice:Cross-contamination68

CUSTOMPROCESSINGUnsafe practice:Cross-contamination69

SPROUTING70

Variety ofSproutsPhoto credit: William Keene71

Radish SproutsPhoto credit: Wikepedia72

Red Clover SproutsPhoto credit: Wikepedia73

Alfalfa SproutsPhoto credit: Wikepedia74

Mung BeanSproutsPhoto credit: Wikepedia75

Broccoli SproutsPhoto credit: Wikepedia76

WheatgrassPhoto credit: Wikepedia77

Small ScaleSproutingBeginning Stage78

Small ScaleSproutingMid stage79

Small ScaleSproutingEnd Stage80

Juice81

Packaged Juicewith aWarning Label82

Regulatory Actions for Non-complianceDuring the inspection, you discovered that theestablishment is conducting a specialized process.What do you do?83

Specialized Processes – Applicable Regulations 3-502.11 Variance Requirement3-502.12 Reduced Oxygen Packaging Without a Variance, Criteria8-103.10 Modifications and Waivers8-103.11 Documentation of Proposed Variance and Justification8-103.12 Conformance with Approved Procedures8-201.13 When a HACCP Plan is Required8-201.14 Contents of a HACCP Plan84

Helpful ResourcesValidation and Verification of HACCP Plans in Retail Food Establishments: ACourse for Retail Food 2.pdfValidation and Verification of HACCP Plans in Retail Food Establishments: ACourse for Retail Food accp/FDA 312: Special Processes at nd-tribal-regulatory-partners-welcomeotedNACCHO Sharing Session Specialized Processes-Reduced Oxygen Packaging.April 25, df85

Validation and Verification ofHACCP Plans in Retail Food Establishments(Food Service and Retail Food Stores)A Course for Retail Food RegulatorsLearner GuideConsulting Curriculum DeveloperPamela Ross-Kung, MS, RSProject ManagerPriscilla Neves, MEd, RS, CFSPMassachusetts Department of Public HealthRevised August 200386

Retail HACCPValidation andVerificationTRAINING MANUALValidation and Verification of HACCP Plans in Retail Food Establishments:A COURSE FOR RETAIL FOOD INDUSTRYFebruary 201987

Sep 12, 2019 · HACCP . Plans in Retail Food Establishments (Food Service and Retail Food Stores) A Course for Retail Food Regulators. Learner Guide. Consulting Curriculum Developer. Pamela Ross-Kung, MS, RS. Project Manager. Priscilla Neves, MEd, RS, CFSP. Massachusetts Depa