Food Safety And Law.docx

FOOD SAFETY AND LAW Hazard Analysis Critical Control Points (HACCP) portfolio Assessment Brief This HACCP report is very much heading in the right direction however I need to ensure that all required elements are included.

The HACCP report should include the following based on the attached Pasta Hut Scenario (can found bellow) From the following headings suggest areas which might be covered by rules, polices or procedures that you would expect Pasta Hut to have included in their prerequisite programme a. b. c. d. e.

Design and facilities Control of operation Maintenance Personal hygiene Training

2. Identification of HACCP Team members & definition of the scope of the study 3. Product description & identified use 4. Construction of the process Flow Diagram (the flow diagram that you have produced is good you just need to check it against the recipe in the scenario) 5. Determination of all Potential Hazards & Completion of Hazard Analysis 6. Identification of preventative measures 7. Determination of CCPs 8. Establishment of a Monitoring System, Critical Limits & Corrective Actions for each CCP 9. Establishment of Verification Procedures 10. Establish of Documentation and Record Keeping

Maximum 10 pages (1000 words excluding diagrams and tables)

1

[Type text] THE PASTA HUT SAFETY SCENARIO The “Pasta Hut Safety Scenario” will require you apply the theoretical and technical aspects of food safety management to a “real life” scenario from a technical manger perspective. You have been employed by director of a company that has just taken over ownership of a chain of five “fast food” Italian restaurants in the X area. Each restaurant has a basic menu including; Spaghetti bolognaise; Pizzas (Range of Toppings); Lasagne; Cannelloni; Tiramisu, (recipe details are provided). Each restaurant is of basic design/layout and rely high quality/low price and a high turnover of customers. You have been employed primarily to develop a food safety management system for the company and to develop and manage a strategy to ensure the future safe production of food throughout the chain. Following a recent food hygiene inspection by the local Environmental Health Department of one of the restaurants (1)the company has been prosecuted and fined for contraventions relating to poor hygiene standards in the kitchen. An internal investigation following the prosecution revealed continuing poor standards in all but one of the restaurants (2). The standard of cleanliness is poor and the kitchens in at least two of the restaurants are suffering from infestation by rodents and/or cockroaches. The kitchen facilities in the remaining restaurant are old, in disrepair and are in need of refurbishment. With the exception of the restaurant that was subject to prosecution, restaurants within the chain have not been subject to an inspection to by the local Environmental Health Department for nearly two years. It is therefore likely that the restaurants will be subject to inspection within the near future and is likely that a further prosecution will ensue unless the company takes urgent action. As part of the internal investigation the new owners of the company has carried out a preliminary audit, which has revealed that the basic state of hygiene in the kitchens leaves much to be desired. This includes, among other things:    

Limited documentation (an attempt to produce a HACCP document for only one of the five main dishes has been made however this has not been implemented or developed further) Poor standards of stock control/stock rotation, Inadequate control over cooking/heating processes, Inadequate control of food prepared in advance.



Inadequate control of preparation and cooling of prepared and part prepared dishes



A general lack of temperature control

The company are extremely concerned as another prosecution or an outbreak of food poisoning will have an adverse impact on the business.

[Type text] RESTAURANT DESIGN & OPERATION

Each restaurant with the exception of the Middlesbrough restaurant has the same basic following design and layout.

Walk in Chiller

Food Preparation Sink

Equipment Wash Sink

2 Wash hand basins Pizza Oven Pizza Preparationarea

Preparation Refrigerated storage under preparation work surfaces

Bainsmarie Cooking Range & Extraction canopy

Pasta Dish PreparationArea

Desert Chiller and service area

Customer seating area

and service area

Corridor leading to rear entrance, customer and staff W.C.

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Each restaurant employs the following staff; 

2 Chefs

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2 Assistant Chefs



2 Chefs Assistants



12 Waiters/waitresses



1 Cleaner

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MENU & PREPARATION Each restaurant operates to a limited standard menu as follows: SPAGHETTI BOLOGNAISE In each of the restaurants bolognaise sauce is produced twice per week, cooled and placed in refrigerated storage. Sufficient bolognaise sauce is removed each day for that days requirements, reheated and hot held in a bainsmarie. The spaghetti cooked in regular batches throughout the day and stored for short periods in a bainsmarie. Ingredients

Preparation & Cooking



Streaky bacon, diced



Olive oil



Onion, finely diced



Celery, finely diced



Carrot, finely diced



Garlic cloves, crushed with a little Once browned the mince is added to the tomato mixture. salt The pan used to brown the mince is then deglazed with Fresh thyme some of the red wine and added to the tomato and meat leaves mix together with the remaining wine and the chicken stock into the tomato and meat mixture. Bay leaf The mixture is brought to the boil before the heat is reduced Dried oregano and the mixture allowed to simmer for about 2 hours.

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  

Chopped tomatoes



Tomato purée



Anchovy essence



Worcestershire sauce



Minced beef



Dry red wine



Chicken stock



Dried spaghetti

The bacon is fried in olive oil. When the bacon is crispy and has released some natural fats, the onion, celery, carrot, garlic, thyme, bay leaf and oregano are added and cook over a medium heat until the vegetables have softened and taken on a little colour. The canned tomatoes are added together with the tomato purée, anchovy essence and Worcestershire sauce. The mince is fried in small batches in a large frying pan until browned using olive oil.

When the meat is tender the mixture is allowed to cool before being placed in a refrigerator The spaghetti cooked in plenty of boiling water with a little olive oil in regular batches throughout the day and stored for short periods in a bains-marie.

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

Salt and ground black pepper

PIZZAS Pizza bases are produced in advance daily and stored at room temperature. Salami and pepperoni used as pizza toppings are purchased from the wholesaler kept in refrigerated storage and sliced three times a week and returned to refrigerated storage until required. Chicken used as a pizza topping is produced is cooked at each of the restaurants twice per week cooled and flaked into a container before being placed in refrigerated storage. Sufficient pizza toppings are removed each day for that day’s requirements storage. The cheese used for the toppings is grated using a mechanical grater every other day and kept in refrigerated storage. All other topping are prepared daily using either fresh, frozen or tinned ingredients. All pizzas are assembled and cooked to order. Ingredients

Preparation and Cooking

For the base: 

Pizza dough flour



Olive oil



Water



Salt For the tomato sauce:



Olive oil



Onion, finely chopped



Garlic, crushed



Bay leafs



Dried oregano



Canned chopped tomatoes



Tomato purée



Salt



Black pepper

Pizza Toppings:

The flour, olive oil, water and salt are mixed together using a bowl mixer The dough is rolled into pizza bases and place onto baking trays. The tomato sauce is produced by gently cooking the onion and garlic in a pan they are soft. The remaining ingredients are added and the sauce simmered for 10 minutes before being allowed to cool. When required a generous amount of tomato sauce is spread over the pizza base(s), leaving a 1cm/½in gap around the edge. The toppings are then added as required and drizzled with olive oil The Pizzas are placed in a pizza oven at 220ºC for about 15-20 minutes or until the base is crisp and the topping is golden.

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Tomato and cheese form the basic pizza ingredients Cheese Feast: 

Mozzarella cheese



Gruyere cheese



Dolcelatte cheese



Parmesan cheese

Popeye Special: 

Cooked spinach



Grated nutmeg



Dried oregano



Mozzarella cheese



Grated parmesan cheese



Pine nuts



Egg

Hot shot: 

Thinly sliced pepperoni



Thinly sliced onion



Chopped jalapeno peppers



Mozzarella cheese



Oregano

For a Four-in-One: 

Thinly sliced pepperoni



Thinly sliced salami



Thinly sliced mushrooms



Mozzarella cheese

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

Tinned anchovies



Olives

For a Seafood and Spice: 

Cooked prawns



Olives



Chilli flakes



Mozzarella cheese



Anchovies

LASAGNE Lasagnes are produced once per week in each restaurant. The lasagnes are portioned and frozen. Sufficient lasagne is removed from frozen storage and defrosted each day for that days requirements,

Ingredients

Preparation and Cooking

For the meat sauce:

The celery, onion and bacon are gently fried in butter until the onion softens and the bacon starts to brown.



Butter



Celery stalks, finely sliced



Unsmoked streaky bacon, chopped



Onions, chopped



Beef mince



Cloves garlic, chopped



Chopped tomatoes



Red wine



Bay leaf



Beef stock cube



Oregano



Basil



Parsley



Black pepper



Tomato pure



Plain flour

The mince and garlic are added and cook gently for about 10 minutes, until the beef has browned. The chopped tomatoes, wine, herbs and seasoning, stock cube, tomato purée and bay leaf are added. The sauce is simmered for approximately 40 minutes. The plain flour is added and stir well to emulsify the oils and thicken the sauce. The béchamel sauce is prepared by first gently heating the milk, cloves and bay leaf into a pan until the milk simmers. The bay leaf and cloves are removed and set aside. The butter is gently heated over low heat, the flour added and stirred to form a paste.

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For the béchamel sauce: 

Full-fat milk



Cloves



Bay leaf



Butter



Plain flour



Single cream



Sheets of lasagne, readyto-cook



Grated parmesan cheese

The heated milk is slowly poured in, whilst whisking. Brought to a simmer and added and heated until it nearly simmers again. Removed from heat and seasoned. Layer of meat sauce is spread on the bottom of a lasagne tray. Covered with dried lasagne sheets covered with a layer of the béchamel sauce, then sprinkle with grated parmesan. This process is repeat three or four times, finishing with the parmesan. The lasagne is topped with some dried herbs and black pepper and put into a Preheat the oven to 200ºC to heat through and brown for about 15-25 minutes. The lasagne is cooled at room temperature portioned and placed in frozen storage.

CANNELLONI Cannelloni’s are produced once per week in each restaurant. The Canneloni’s are frozen. Sufficient Cannelloni’s are removed from frozen storage and defrosted each day for that days requirements,

Ingredients 

Fresh pasta dough



Olive oil



Fresh cep mushrooms



Butter



Onion, peeled and very finely sliced



Minced beef



Salt



Freshly ground black pepper



Nutmeg



Egg yolk



Finely chopped parsley

Preparation and Cooking The pasta dough is rolled out on a lightly floured surface to make sheets of pasta. The pasta is cooked for 4 minutes in plenty of boiling water. The pasta is removed and dried on a clean towel. Finely chop the ceps. The filling is produced by frying the onion until soft in butter. The beef is then added together with the ceps and continue frying until the beef is browned. Salt, pepper and nutmeg are added to taste and set aside to cool slightly. Next the egg yolk and the parsley are stirred into the filling mixture and mix well. The filling is spooning into the middle of each piece of pasta. A piece of mozzarella is placed on top of the filling and the pasta squares are rolled around the filling to make cannelloni tubes. Tomato sauce is placed in the bottom of a large ovenproof dish.

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

Mozzarella cheese cut into 8 segments

The cannelloni are laid side by side, over the sauce and covered with the remaining sauce.



Tomato sauce

Finally the cannelloni are sprinkled with parmesan cheese before being placed in frozen storage.



Freshly grated parmesan cheese

The cannelloni are defrosted as require and bake for 20 minutes at 220ºC.

TIRAMISU The tiramisu are made several times per day and placed in refrigerated storage. Ingredients 

Raw egg yolks



Caster sugar



Kahulua or coffee liqueur



Mascarpone cheese



Strong espresso, cold



Boudoir biscuits



Plain chocolate, finely grated



Cocoa powder

Preparation

Using an electric whisk the egg yolks and caster sugar are beaten together until pale and thick. The mascarpone is added and whisked slowly until the mixture is pale and smooth. The coffee liqueur is added and whisked gently. In a separate bowl the coffee and remaining coffee liqueur are mixed. Half of the boudoir biscuits are dipped into the coffee mixture place in the bottom of glass coffee cups or small bowls Mascarpone mix is spooned over and sprinkled with chocolate. This is repeated with another layer of biscuits, mascarpone and chocolate. The dishes are covered and refrigerate for 2 hours and dust with cocoa powder before serving.

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This is my report which I need you to make it 1000 words and I need to do the work which is the red colour.

Contents 1.

A HACCP report for PASTA HUT .................................................................................................... 13 1.1 Chosen Food: Cannelloni Dish .................................................................................................... 13

2.

Cooking Cannelloni ....................................................................................................................... 16

3.

HACCP Decision matrix ................................................................................................................. 17

4.

Floor plan ...................................................................................................................................... 19

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1. A HACCP report for PASTA HUT The aim of this report is to provide an overview of the restaurant’s layout and also analyse the HACCP practices. To provide an element of realism a pasta dish will be used based on a Tesco product offered in its super markets. Pasta hut is an amazing place for pasta lovers. It is typical street food corner where you can buy your favourite pasta at a reasonable price. The pasta tastes great. The sauce is quite thick and cheesy.

1.1 Chosen Food: Cannelloni Dish (I was provided with a recipe and part of the Pasta Hut scenario. The

Pasta Hut Chain is

not a supermarket chain– the scope of the HACCP study should relate to the scenario) The HACCP system can be applied throughout the food chain from the primary producer to the final consumer. Besides enhancing food safety, other benefits in applying HACCP include more effective use of resources and more timely response to food safety problems. In addition, the application of the HACCP system can aid inspection by food control regulatory authorities and promote international trade by increasing buyer confidence in food safety. TYPICAL VALUES

100g Contains:

Each pack: 400g contains:

ENERGY PROTEIN CARBOHYDRATE SUGARS FATS FAT: SATURATES FIBRE SALT

712KJ (171 kcal) 7.9g 11.7g 4.1g 10.0g 3.7g 1.4g 0.4g

2849KJ (683 kcal) 31.5g 46.6g 16.6g 39.9g 14.8g 5.7g 1.7g

Table 1Cannelloni Dish

.

[Type text] For the most part this is a meal which is typical for supermarket meals. Therefore as part of the assignment a thorough investigation needs to talk place which involves assessing the ingredients and individual components, this provides insights into key factors such as shelf life. In the table below, lists of components have been provided and the storage methods used to keep the meal as fresh as possible.

(NEED to define my HACCP team here AND consider GMP) The team may include specialists: 

who understand the biological, chemical or physical hazards connected with a particular product or dish.



who have responsibility for, or is closely involved with, the technical process of manufacturing the product under study .



who have a working knowledge of the hygiene and operation of the process plant and equipment



any other person with specialist knowledge of hygiene or food technology. GMP is the system to ensures that product meet food safety,quality and legal requirements. Ten GMP principles : 

Writing procedure



Following writing Procedure



Documenting for traceability



Designing facilties and equipment



Validating work



Job competence



Cleanliness



Component control



Auditing for Compliance

[Type text] Free Range Egg Pasta N/A – Until the pasta is fully combined then it must be refrigerated

Meat Filling Garlic puree Beef Sundried tomato paste Pork Panchetta White wine

Ambient Environment

Eggs

Dry Environment

Durum Wheat Semolina

Carrot Chianti: Red Wine Celery Tomatoes Tomato passata Bread crumbs Salt Oregano Onion powder Sugar Salt Extra Virgin Olive Oil Parsley Mustard powderPectin Black pepper White pepper Thyme

Refrigerated Environment

Beef Stock Tomato paste Beef Extract Leek puree Carrot puree

Cheese Sauce: Full Fat Soft Cheese Milk Mascarpone

Parmigiano Reggiano Cheese

Corn flour

table 2 Components

Step no. 1 2 3 4 5 6 7 8 9

Procedure Prep Boil Fry Bake Mix Roll Pack Store Reheat

table 3Dish components

BIO

Dish components Type of hazard CHEM PHY

Prevention MICR

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2. Cooking Cannelloni The flow chart depicts the different steps required when making the Cannelloni dish. There are distinct phases which can be summarised briefly below and then expanded upon:

Beef stock creation

Make meat sauce for pasta, needs to be at handleable temperature

make cheese (or use ready made) and scatter over tubed pasta

Cook product until the piping hot ensuring cheese is slighly burnt

freeze product once cooled

Package as desiired

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(Need to add time and temperatures etc.) To eat straight away, heat oven to 200C/180C fan/gas 6 and cook for 40-45 mins until the it is tender and topping golden. Defrost frozen cannelloni thoroughly, then cook as above for 50 mins-55 mins.

3. HACCP Decision matrix(need to Identify CCPs using a decision matrix) A CCP is a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or, reduce it to an acceptable level.

Beef Stock Process

Hazard Type

Prevention measure (need to set some Critical and Target Limits for your CCPs also need to consider monitoring of CCPs, corrective actions and responsibilities )

-

BIO

CHEM

PHY

MICR

1

Prepare

n/a

Chemical Cleaning

Skins, knifes and peels

Vegetable left unwashed – germs

Keep work space clean and dispose of rubbish.

2

Boil

Hot liquids

n/a

n/a

Undercooked

Constantly check product

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Store

Growth of bacteria after time

n/a

n/a

9

Reheat Table 4

Must be boiled

n/a

n/a

Cool to room temp before storing

Bring to room temperature store at or below 8’C, reducing bacteria

Eradicate bacteria

Meat Sauce Process 1

Preparation

2 3 6

Boil Fry Roll

7

Package

8 9

storage reheating

Type of hazard BIO

CHEM

Prevention

PHY

MICR

Skins, knifes and peels Water (hot) Hot oil Make sure disk and everything else remain separate entities Encase complete product

Have clean surfaces, preventing bacteria

Past sell by date

Suitable ingredient storage Monitor temperature and time length Keep oil temperature optimal Maintain cleanliness

Freshness, hygiene and shelf life are expanded by having good packaging

Undercooked

Fridge storage Monitor length of cooking time especially for egg pasta

Table 5

Pasta Process

Type of hazard BIO

1 5

Preparation Kneading

6

Roll

7

Package

8

Storage

9

Reheating table 6

CHEM

Eggs (salmonella) Wash hands reducing germs

PHY

Prevention MICR

Egg shell Bacteria, germs, dirt located under nails Splinters (Rolling pin)

Store in fridge or at 8’C.

Use separate dishes for eggs Non use of gloves and hand skin issues, i.e. sores Use metal rolling pin or machine

Salmonella?

Baking paper can be used to avoid pasta sticking Store are chilled temperature Cook at high temp.

Cheese Sauce Process 1

Preparation

2

Boil

Type of hazard BIO Date of cheese

Prevention CHEM

PHY

MICR

Note sell by date Use protective wear

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storage

9

reheating

Once over pasta, store immediately

Ensure thorough reheating killing bacteria

table 7

(Need to include validation/verification) Areas used for preparation are far from sinks and close to cooking area

STEPS IN ESTABLISHING VERIFICATION PROCEDURES 1. Determine the appropriate verification procedure to ensure that each CCP and critical limit is adequately controlled and monitored. 2. For each CCP, determine procedures to ensure that employees are following your established procedures for handling product deviations and for recordkeeping. 3. Identify the frequencies for conducting any verification checks and the records where the results will be recorded. 4. Enter the details on the appropriate verification form for future reference.

4. Floor plan (Changes to the floor plan / lay out fall within GMP therefore could be included earlier) To map a warehouse or other storage space, you first must identify areas where product quality may be at risk because of unacceptable variations in temperature and humidity.   

Layout of racks, shelves, and pallets, which obstruct airflow. Locations near sources of heat or cold, such as the roof and exterior walls, windows, and loading dock. Temperature gradients between the cooler floor and warmer air near the ceiling.

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Oven is close to chiller and may be effected Staff and customers share toilets Customers can access kitchen Refuse is removed from here

Areas used for preparation are far from sinks and close to cooking area

Staff entrance

Pasta Prep and stove

chiller Hand wash sink

Food prep sink

Baines -marie

Pizza Prep and Pizza Oven

Staff toilets

Dessert display cabinet

Customer toilets

counter

Customer seating area

Chiller and ovens have now been separated which should prevent any fluctuation of the chiller temperature should remain below 8’C. Previously there was too much access being allowed to sensitive areas, furthermore, despite the fridges and freezers still being below the preparation desks, this arrangement allows a greater amount of space for the preparation of pasta and pietas.