292 Chilled foods Table 11.1 Risk classes of chilled foods Risk Typical Critical Relative Required minimum Required manufacturin class shelf-life hazard risk eat treatment MA HA HCA 1 1 week Infectious High Customer cook pathogens ( minimum70°C, 2 1-2 weeks Infectious Low Pasteurization by pathogens manufacturer minimun70° 3 >2 weeks Infectious Low Pasteurization by manufacturer and spore- ( minimun90°C, O min aste manufacture minimun90°C 10 min) meat, fish etc; Class 2 ts made from a mixture of Class 3: Products cooked or baked and assembled or primary Products cooked in-pack senic area; HCA: High-care area. vide and other foods with preservation and pasteurisation combinations that ensure long shelf-lives under chill conditions. These products are processed to free them of spoilage bacteria and pathogens capable of growth at chill temperatures, and hence allow very long shelf-lives(42 days or so). Therefore processing, handling and packaging must specifically ensure that they are free of infectious pathogens and the spore-forming pathogens capable of growing under chilled conditions. There is still a lack of knowledge on realistic safety boundaries and the risks associated with these products, with respect to the most severe hazard non-proteolytic Clostridium botulinum (Peck 1997). The determinants of effectiveness of complex combination preservation system that rely on mild heating and chilled storage are not fully understood 11.2.3 Safety and quality control Good manufacturing practice Good manufacturing practice(GMP) covers the boundaries and fundamental principles, procedures and means needed to design an environment suitable for the production of food of acceptable quality. Good hygienic practice(GHP) describes the basic hygienic measures that establishments should meet and
vide and other foods with preservation and pasteurisation combinations that ensure long shelf-lives under chill conditions. These products are processed to free them of spoilage bacteria and pathogens capable of growth at chill temperatures, and hence allow very long shelf-lives (42 days or so). Therefore processing, handling and packaging must specifically ensure that they are free of infectious pathogens and the spore-forming pathogens capable of growing under chilled conditions. There is still a lack of knowledge on realistic safety boundaries and the risks associated with these products, with respect to the most severe hazard non-proteolytic Clostridium botulinum (Peck 1997). The determinants of effectiveness of complex combination preservation systems that rely on mild heating and chilled storage are not fully understood. 11.2.3 Safety and quality control Good manufacturing practice Good manufacturing practice (GMP) covers the boundaries and fundamental principles, procedures and means needed to design an environment suitable for the production of food of acceptable quality. Good hygienic practice (GHP) describes the basic hygienic measures that establishments should meet and Table 11.1 Risk classes of chilled foods Risk Typical Critical Relative Required minimum Required manufacturing classa shelf-life hazard risk heat treatment classb MA HA HCA 1 1 week Infectious High Customer cook ✓ (✓) pathogens (minimum 70ºC, 2 min.) 2 1–2 weeks Infectious Low Pasteurization by ✓ ✓✓ pathogens manufacturer (minimum 70ºC, 2 min.) 3 2 weeks Infectious Low Pasteurization by ✓ ✓ pathogens manufacturer and spore- (minimum 90ºC, formers 10 min.) 4 2 weeks Spore- Low Pasteurization by ✓ ✓ formers manufacturer (minimum 90ºC, 10 min.) Notes a Class 1: Raw chill-stable foods, e.g. meat, fish etc.; Class 2: Products made from a mixture of cooked and low-risk raw components; Class 3: Products cooked or baked and assembled or primary packaged in a high-care area; Class 4: Products cooked in-pack. b MA: Manufacturing area; HA: Hygienic area; HCA: High-care area. 292 Chilled foods
Microbiological hazards and safe process design 293 Raw Materia Storage on Receipt Preparation Chilling Prepared Raw Material EFER HYGIENI Component AREA Assembly Primary Packaging Secondary Packaging Chilling Distribution Retailing Physical and staff separation obligatory Fig. 11. 1 Typical flow diagram for the production of chilled foods prepared from only raw components (Class 1) which are pre-requisites to other approaches, in particular HACCP. GMP codes and the hygiene requirements they contain are the relevant boundary conditions for the hygienic manufacture of foods and should always be appli Governments(see Anon. 1984, 1986), the Codex Alimentarius Committee on Food Hygiene(FAO/WHO) and the food industry, often acting in collaboration with food inspection and control authorities and other groups have developed GMP/GHP requirements ( Jouve et al. 1998). Generally GHP/GMP requirements over the following the hygienic design and construction of food manufacturing premises the hygienic design, construction and proper use of machinery
which are pre-requisites to other approaches, in particular HACCP. GMP codes and the hygiene requirements they contain are the relevant boundary conditions for the hygienic manufacture of foods and should always be applied. Governments (see Anon. 1984, 1986), the Codex Alimentarius Committee on Food Hygiene (FAO/WHO) and the food industry, often acting in collaboration with food inspection and control authorities and other groups have developed GMP/GHP requirements (Jouve et al. 1998). Generally GHP/GMP requirements cover the following: • the hygienic design and construction of food manufacturing premises • the hygienic design, construction and proper use of machinery ! "! # # # $ $ %% Fig. 11.1 Typical flow diagram for the production of chilled foods prepared from only raw components. (Class 1) Microbiological hazards and safe process design 293
294 Chilled foods Storage on Receipt Raw Material omponents Cooked Components Cook Component Disinfection Components Chilled HYGIE AREA Component Assembly Primary Packaging Secondary Packaging Distribution Physical and staff separatic Fig. 11.2 Typical flow diagram for the production of chilled foods prepared from both cooked and raw components( Class 2) cleaning and disinfection procedures(including pest control) general hygienic and safety practices in food processing including the microbiological quality of raw materials the hygienic operation of each process step the hygiene of personnel and their training in hygiene and the safety of
• cleaning and disinfection procedures (including pest control) • general hygienic and safety practices in food processing including – the microbiological quality of raw materials – the hygienic operation of each process step – the hygiene of personnel and their training in hygiene and the safety of food. ! "! # # # $ $ %% $ % Fig. 11.2 Typical flow diagram for the production of chilled foods prepared from both cooked and raw components. (Class 2) 294 Chilled foods
Microbiological hazards and safe process design 295 Raw Material Precooked Components Reel Sealed packs Raw Material Preparation Intermediate HYGIENIC AREA CookIn Disinfection HIGH AREA Primary Packaging Secondary Packaging Distribution Retailing Physical and staff separation obligatory Fig. 11.3 Typical flow diagram for the production of pre-cooked chilled meals from cooked components( Class 3) HACCP The Hazard Analysis Critical Point Control System(HACCP)is a food management system using the approach of identifying hazards and contre the critical points in food handling and processing to prevent food safety problems. It is a system or approach that can be used to assure food safety in all scales and types of food manufacture and is an important element in the overall management of food quality and safety. The widespread introduction of
HACCP The Hazard Analysis Critical Point Control System (HACCP) is a food safety management system using the approach of identifying hazards and controlling the critical points in food handling and processing to prevent food safety problems. It is a system or approach that can be used to assure food safety in all scales and types of food manufacture and is an important element in the overall management of food quality and safety. The widespread introduction of ! "! # # # $ $ %% $ % ! ! # # # Fig. 11.3 Typical flow diagram for the production of pre-cooked chilled meals from cooked components. (Class 3) Microbiological hazards and safe process design 295
296 Chilled foods Raw material Intermediate Stor Primary Packaging HYGIENIC Chilling Distribution Fig 11.4 Typical flow diagram for the production of chilled foods cooked in their own ackaging prior to distribution. ( Class 4) HACCP has promoted a shift in emphasis from end-product inspection and testing to preventive control of hazards at all stages of food production, but especially at the critical control points(CCPs). As such, it is a management technique ideally suited to the manufacture of chilled foods, where many
HACCP has promoted a shift in emphasis from end-product inspection and testing to preventive control of hazards at all stages of food production, but especially at the critical control points (CCPs). As such, it is a management technique ideally suited to the manufacture of chilled foods, where many ! # ! "! # # Fig 11.4 Typical flow diagram for the production of chilled foods cooked in their own packaging prior to distribution. (Class 4) 296 Chilled foods