Understanding HACCP in a Commercial Kitchen
The HACCP (Hazard Analysis Critical Control Point) system identifies points in the food production process at which hazards can contaminate food and make it unsafe. The HACCP method then calls for not only placing controls at those points but also creating a 7-step protocol to prevent contamination and maintain safety in an organized way.
If you’re curious about how to apply the HACCP approach in a foodservice establishment, this guide to understanding HACCP (Hazard Analysis Critical Control Point) in a commercial kitchen will help you develop a 7-step process for ensuring food safety. With this systematic, organized and measurable approach, you can maintain food quality as efficiently as possible.
1. Conduct a Hazard Analysis
The first step in the HACCP system is identifying hazards, biological, chemical and physical contaminants that can enter food and cause illness. Examples of food safety hazards include:
- Biological - Bacteria, viruses, molds, parasites
- Chemical - Pesticides, cleaners, machine oils
- Physical - Hairs, glass, insects and other foreign objects
For example, as reported by the CDC, 1 out of every 25 packages of chicken sold at US grocery stores is contaminated with salmonella, a bacterial infection that causes diarrhea, fever and dehydration. Considering the prevalence of salmonella and the seriousness of infection, a hazard analysis for chicken would determine that salmonella is a potential biological hazard.
Chemical hazards like dishwashing detergent can pose a risk, too. Since it contains chemicals such as phosphates and alcohol ethoxylates, dishwashing detergent residue on improperly-washed dishes can contaminate food and cause stomach irritation, as well as make the food taste unpleasant.
The HACCP method also identifies physical hazards such as human hair. In addition to ruining your customers’ appetite, human hairs in food can pose a choking hazard and transmit fungal infections like ringworm.
Considering the number of biological, chemical and physical hazards that can contaminate food, it’s important to identify them and understand their seriousness. By understanding the risks to food safety in a commercial kitchen, you can then start developing a plan to prevent them.
2. Determine the Critical Control Points (CCPs)
After identifying the hazards, the next step in the HACCP system is determining the critical control points (CCPs), which are points or steps in the food production process at which contamination from hazards can be prevented or minimized.
For instance, in regards to salmonella, the critical control point is the cooking process. When it comes to detergent residue on dishes, the hazard can be prevented at the end of the dishwashing cycle. In regards to hair contamination, any time at which kitchen staff members come into contact with food, especially if hair is exposed, is a cause for concern.
3. Establish Critical Limits
Once the critical control points are identified, you need to determine critical limits, minimum or maximum levels that must be met in order to prevent or minimize the risk of a hazard. HACCP critical control points should be observable and measurable so that they can be applied objectively and systematically.
With respect to salmonella, the critical control point is making sure the internal temperature of chicken reaches at least 165°F (73.9°C) for at least 15 seconds during the cooking process. Concerning rinse aid residue, the maximum amount of contamination allowed is none; likewise, the critical limit for human hairs in food is zero as well.
4. Establish Monitoring Procedures
After determining the critical limits, the next step in the HACCP system is implementing a plan for ensuring that critical limits are met. The plan should also identify who is responsible for verifying and recording that critical limits are met.
For instance, the staff member who is responsible for cooking chicken should use a thermometer to make sure the internal temperature reaches at least 165°F (73.9°C). Once the staff member is done preparing the chicken, he or she should make a written record indicating that the chicken did in fact reach the desired temperature.
In the case of dishwashing detergent residue, a staff member needs to check the dishes at the end of the dishwashing cycle to make sure there’s no rinse aid residue on the dishes. If no residue is found, the staff member should make a written record stating that no residue was found.
Although all staff members should visually inspect food items for human hair contamination, the last person in the production process before food is packaged or given to customers should do a final quality control check. Since making a written note for every item may slow down kitchen operations, it may be better to only make note of cases of hair contamination.
5. Establish Corrective Actions
The monitoring process may reveal a deviation, a case when the critical limit isn’t met. When this happens, a well-developed HACCP plan presents a set of corrective actions, steps that should be taken when a critical limit isn’t met.
For example, the staff member who is cooking chicken breast may find that the thermometer reads less than 165°F (73.9°C) at the end of the routine cooking time. In this case, the corrective action is to continue cooking the chicken until the thermometer indicates that the critical limit (an internal temperature of 165°F or 73.9°C) has been met.
If dishwashing detergent residue is found on a plate, the dish should be returned to the dishwasher and washed again. Washing the dish by hand is another potential solution. In the case of human hair contamination at any point during the production process, the food item should be discarded and replaced.
6. Establish Verification Procedures
It’s also important to review your HACCP method on occasion to evaluate its effectiveness. In addition, it’s also essential to verify that staff members are implementing the system correctly.
In regards to the dangers of salmonella in chicken, commercial kitchen managers should review staff member logs on a daily basis to make sure the internal temperature is measured every time that chicken is prepared. Managers can also review records of detergent and foreign object checks to verify that the established procedures are being followed.
In addition to employee records, monitoring customer complaints of foodborne illness can be a good way to determine if chicken is being cooked properly, dishes are being washed thoroughly and hair nets are being worn correctly. Managers may also want to look at social media posts to see if there are any informal customer complaints, too.
7. Establish Record-Keeping and Documentation Procedures
The final step of the Hazard Analysis Critical Control Point system is developing ways to document that the plan is being followed over time. This step also includes reviewing logs and records to identify potential weaknesses and opportunities for improvement within the commercial kitchen.
For example, a commercial kitchen manager might save chicken temperature logs for multiple months and analyze them. If it seems that staff members frequently need to extend the cooking time, equipment issues may be the cause, not operator error. In that case, the equipment might need maintenance.
Likewise, if a review of documented customer complaints reveals that detergent residue is contaminating food more frequently than in the past, the warewashing unit may require maintenance. Or, it might be better to implement a 3-basin warewashing system so staff members have more direct control over detergent usage.
Similarly, if a pattern of hair contamination emerges in afternoon shift logs, those staff members may require more training. Perhaps the food handlers aren’t wearing their hair nets correctly, or maybe they’re unaware of hazards posed by facial or body hair. Whatever the cause, identifying the staff members who may need more training makes correcting the issue much easier.
More Food Safety & Hygiene Tips
No matter if you’re head chef or running plates, it’s important to know best food safety practices. Understanding common safety mistakes, benefits of certification and learning best hygiene practices will provide safe food production and storage. To ensure you’re protecting your staff and customers from food-borne illnesses, check out our article on Food Safety and Hygiene in a Commercial Kitchen.