Develop and implement a food safety plan

1. What are the requirements for food businesses with regards to a food safety plan

according to the Food Standards Code?

The food safety standards aim to lower the incidence of food borne illness. They
place obligations on Australian food businesses to produce food that is safe and
suitable to eat, and also place health and hygiene obligations on food handlers.

Requirements

 General hygienic and sanitary practices to be followed by food business

operators applying for registration - Petty food operators and Street food
vendors
 General hygienic and sanitary practices to be followed by food business
operators applying for license- Manufacturing/ processing/
packaging/storage/distribution
 General hygienic and sanitary practices to be followed by food business
operators applying for license- Milk and milk products
 General hygienic and sanitary practices to be followed by food business
operators applying for license- Slaughter house and meat processing

2. You are in the process of developing a food safety program. What does this

require for each of the following steps?

a) Create a HACCP team

A HACCP Team can be defined as being a group of people who have adequate
skills and knowledge applicable to the development and implementation of a
HACCP based food safety program.  The requirement to assemble a HACCP team
is documented in Codex HACCP at preliminary step 1 – Assemble the HACCP
team.
b) Describe the products

First, the HACCP team provides a general description of the food, ingredients and
processing methods. Then the method of distribution should be described along
with information on whether the food is to be distributed frozen, refrigerated or at
ambient temperature.

c) Describe the products’ uses

The use should be based on the expected uses of the product by the end user or
consumer. In specific cases, vulnerable groups of the population, e.g. institutional
feeding, may have to be considered.

d) Develop a process flowchart

The flow diagram should provide a clear, simple outline of all the steps involved in
the process that are directly under the control of the establishment. (The flow
diagram can also include steps in the food chain which come before and after the
processing that occurs in the establishment.)

The diagram can be a block-type design — it should does not need to be as

complex as engineering drawings. Also, including a simple schematic of the
facility can be useful for understanding product and process flow.

e) Review the flowchart:

Review of the operation to verify the accuracy and completeness of the flow

diagram. Modifications should be made to the flow diagram as necessary and
documented. After these five preliminary tasks have been completed, the seven
principles of HACCP are applied

f) List all potential hazards:

The HACCP team should list all of the hazards that may be reasonably expected to
occur at each step from primary production, processing, manufacture, and
distribution until the point of consumption.

The HACCP team should next conduct a hazard analysis to identify for the
HACCP plan which hazards are of such a nature that their elimination or reduction
to acceptable levels is essential to the production of a safe food.

In conducting the hazard analysis, wherever possible the following should be

included:

 the likely occurrence of hazards and severity of their adverse health effects;
 the qualitative and/or quantitative evaluation of the presence of hazards;
 survival or multiplication of microorganisms of concern;
 production or persistence in foods of toxins, chemicals or physical agents;
and,
 conditions leading to the above.

The HACCP team must then consider what control measures, if any, exist which
can be applied for each hazard.

g) Determine critical control points

A critical control point is defined as 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. The potential hazards that are reasonably likely to cause illness or injury in
the absence of their control must be addressed in determining CCPs.

One strategy to facilitate the identification of each CCP is the use of a CCP
decision tree. (Keep in mind that a decision tree is merely a tool; it is not a
mandatory element of HACCP, nor is it a substitute for expert knowledge.)

Examples of CCPs may include:

 Chilling
 Thermal processing
 Product formulation control
  Testing ingredients for chemical residues
 Testing product for metal contaminants

h) Establish critical limits for each CCP

A critical limit is a maximum and/or minimum value to which a biological,

chemical or physical parameter must be controlled at a CCP to prevent, eliminate
or reduce to an acceptable level the occurrence of a food safety hazard. A critical
limit is used to distinguish between safe and unsafe operating conditions at a CCP.
Critical limits should not be confused with operational limits which are established
for reasons other than food safety.

Critical limits may be based upon factors such as:

 Temperature
 Time
 Physical dimensions
 Humidity
 Moisture level
 Water activity

i) Decide on monitoring systems for each CCP

The intent of the HACCP system is to focus control at CCPs". An application of

the CCP decision tree on the catchment area. At each step in the process, the
potential hazard to water quality and the controls to prevent the determined critical
control points, a monitoring system, the critical limits of CCPs' 

j) Establish corrective actions

No system is perfect, so when preventive measures fail, corrective actions must be

in place to prevent potentially hazardous foods from reaching consumers.
Corrective actions should:
  Determine and correct the cause of non-compliance
 Determine the disposition of non-compliant product
 Record the corrective actions that have been taken

k) Establish verification procedures

Verification is defined as those activities, other than monitoring, that determine the
validity of the HACCP plan and that the system is operating according to the plan.

One aspect of verification is evaluating whether the facility’s HACCP system is

functioning according to the HACCP plan. An effective HACCP system requires
little end-product testing, since sufficient validated safeguards are built in early in
the process. Therefore, rather than relying on end-product testing, firms should rely
on frequent reviews of their HACCP plan, verification that the HACCP plan is
being correctly followed, and review of CCP monitoring and corrective action
records.

l) Determine record keeping and documentation requirements

Generally, the records maintained for the HACCP System should include the
following:

1. A summary of the hazard analysis, including the rationale for determining

hazards and control measures
2. The HACCP Plan
o Listing of the HACCP team and assigned responsibilities
o Description of the food, its distribution, intended use and consumer
o Verified flow diagram
o HACCP Plan Summary Table that includes information for:
 Steps in the process that are CCPs
 The hazard(s) of concern
 Critical limits
 Monitoring
 Correction actions
 Verification procedures and schedule
  Record-keeping procedures

3. You have decided on monitoring systems for each Critical Control Point and

established corrective actions. Who must be involved when these are

implemented as part of the new Food safety plan? Why?

Hazard Analysis Critical Control Points (HACCP) is a system which provides the
framework for monitoring the total food system for each Critical Control Point and
established corrective actions. Since its inception in the 1960s as part of space
travel, the application of HACCP principles has expanded throughout the food
industry. The Food Safety Modernization Act (December 2010) is expected to lead
to further adoption of the concept. This page briefly introduces the concept of
HACCP and its evolution into a Food Safety Plan.

Reasons for this are:

 Focuses on identifying and preventing hazards that may render food unsafe
 is based on sound science
 permits more efficient and effective government oversight, primarily
because the recordkeeping allows investigators to see how well a firm is
complying with food safety laws and following practices that reduce the risk
of unsafe food over a period rather than how well it is doing on any given
day
 places responsibility for ensuring food safety appropriately on the food
manufacturer or distributor
 helps food companies compete more effectively in the world market
 reduces barriers to international trade.

4. Due to a number of staff absences, you are required to rotate different staff

through the larder section to temporarily fill the positions. How will you ensure

these staff will follow the requirements set out in the food safety program relevant
for the larder section? What would this require in terms of record keeping?

To ensure these staff will follow the requirements set out in the food safety
program relevant for the larder section by:

Food Service staff will receive Food Safety training provided by State or local food
service authorities.

• Staff and volunteers will receive a written copy of this policy in their orientation
packets before beginning work at the center.

• All staff will have training on food safety.

• Written instructions are posted in food preparation areas.

Training them will be essential on how to the larder section operates.

They will need to be consistent in record keeping for review to ensure that
everything is in order.

5. You have implemented the food safety program. Provide details of what will
you need to do to ensure all aspects are followed correctly.

Constant review of the program

\Regular follow ups on the program.

Training of all the staff members

6. Your sous-chef informs you that an uncontrolled food hazard has occurred
which could have critical implications if not attended to swiftly. What will be your
actions including administrative requirements?

 Implement the necessary hazard control procedure on the food.

 Try to find out the cause of the hazard and ways to control it

7. Explain the meaning of contaminant, contamination and potentially hazardous

foods as defined by the Australia New Zealand Food Standards Code

contaminant means any biological or chemical agent, foreign matter, or other
substances that may compromise food safety or suitability. Contamination- f ood
that has been corrupted with another substance – either physical, biological or
chemical . Potentially Hazardous Food is a term used by food safety organizations
to classify foods that require time- temperature control to keep them safe for
human consumption. A PHF is a food that:

 Contains moisture - usually regarded as a water activity greater than 0.85

 Contains protein

 Is neutral to slightly acidic - typically having a pH between 4.6 and 7.5

8. What are the environmental conditions and storage temperatures for the main

food categories and frozen foods?

Always store perishable foods in the refrigerator at 40 °F ( 4.4 °C ) or below or in

the freeze at 0 °F (- 17.8 °C ). Freezer Storage. Keep your freezer at zero degrees
( 0°F ) or below to maintain the quality of frozen foods. Most foods will maintain
good quality longer if the freezer temperature is -10°F to -20°F. At temperatures
between 0°F and 32°F , food deteriorates more rapidly.

9. List four (4) techniques which can be used to monitor food safety and provide 1

example for each. What would this require when temperatures are measured

and/or monitored?

The head chef monitoring and recording items produced by others to ensure that
they meet acceptable standards and quality. • Temperature logs of equipment, such
as fridges and freezers. • Cleaning schedules and completed documentation. •
Maintenance records and requests. • Records regarding health and safety

10. List the three (3) main types of food contamination and provide examples of
how

these are potentially caused:

  Biological contamination - caused by bacteria, viruses or parasites
 Chemical contamination - aflatoxin
 Physical contamination - hair, glass, metal, pests, jewellery, dirt and fake
nails.

11. What are the common conditions for the development of microbiological

contamination? List five (5) examples how microbiological contamination can be

controlled or prevented.

First, there must be a reservoir (i.e., a location where an unusually high

concentration of microorganisms is present). Second, the microorganisms must be
allowed to reproduce. Favourable conditions are needed for reproduction to occur.
For example, fungal growth is usually optimized when moisture levels are high.
Last, the microorganisms must be released into the air.  Air filtration and air
change rates should be set to ensure that the defined clean room class is attained.

 Ambient temperature and humidity should not be uncomfortably high.

 Materials access must be via specified routes – generally via air locks.

12. What is the ‘temperature danger zone’?

The temperature danger zone is food temperatures between 41 and 135 degrees
Fahrenheit, and the most rapid bacteria growth occurs between 70 and 125 degrees
Fahrenheit

13. What is the two-hour and four-hour rule applied to hazardous foods which have

been cooked or following a cooking process?

The 2 Hour / 4 Hour Rule tells you how long freshly potentially hazardous foods *,
foods like cooked meat and foods containing meat, dairy products, prepared fruits
and vegetables, cooked rice and pasta, and cooked or processed foods containing
eggs, can be safely held at temperatures in the danger zone
 14. What is the requirement for the 2 hour/4 hour guide which applies to ready-to-
eat, potentially hazardous food? How is this calculated and what needs to be done
according to the time is exposed in the danger zone?

 Food held between 5°C and 60°C for less than 2 hours can be used, sold or
put back in the refrigerator to use later.
 Food held between 5°C and 60°C for 2-4 hours can still be used or sold, but
can’t be put back in the fridge.
 Food held between 5°C and 60°C for 4 hours or more must be thrown away.

Studies show that food can be safely held out of temperature control for short
periods of time without significantly increasing the risk of food poisoning. The
time that food can be safely held between 5°C and 60°C is referred to as the ‘4-
hour/2-hour rule.

It takes time for food poisoning bacteria to grow to unsafe levels.

15. Create a cleaning schedule (or use an existing one) relevant to your work area

and the food safety plan you will develop for assessment 2 in this unit of

competency and include:

STEP 1:  CREATE A MASTER TASK LIST

Before you can decide when to clean you must first know what to clean, and how
often. Thus before you can create a cleaning schedule that works for your life and
your schedule, you need to assess your own home and cleaning needs.

STEP 2:  PICK THE BEST PLAN FOR YOU (CHOOSE ONE)

The next thing you need to do is figure out what sort of cleaning plan will work
best for your life and your schedule. Are you the kind of person who wants to do a
little every day, or would you rather tackle it all at once so that you don’t have to
think about it for the rest of the week.

STEP 3:  FILL IN YOUR SCHEDULE

This is the easy step! Once you’ve determined what sort of cleaning plan will work
best for your household, just use the handy printables in this post to fill in your
cleaning schedule.

16. List the six (6) high risk customer groups who are more susceptible to harm
from food contamination and explain the reasons for the risk for each group:

Some customer groups are particularly susceptible to food poisoning, and the
dangers it presents. When preparing food for any of the following groups, take
extra special care to avoid contamination:

1. Adults Aged 65 and Older

Older adult sexternal icon have a higher risk because as people age, their immune
systems and organs don’t recognize and get rid of harmful germs as well as they
once did.

2. Children Younger Than 5 Years

Young children external icon have immune systems that are still developing, so
their body’s ability to fight germs and sickness isn’t as strong. Food poisoning can
be particularly dangerous for them because illness can lead to diarrhea and
dehydration.

3. People with Weakened Immune Systems

People with weakened immune system sexternal icon due to diabetes, liver or
kidney disease, alcoholism, and HIV/AIDS; or receiving chemotherapy or
radiation therapy cannot fight germs and sickness as effectively.

4. Pregnant Women
Pregnant women external icon are more likely than other people to get sick from
certain germs.

Children: Children are more susceptible to food borne illnesses, as their immune
systems are still developing and are not as strong as adults.
The elderly: Older people are more susceptible to food poisoning, as when you get
older, your immune system and natural defense are weakened.

17. What is the role of local government in determining audit requirements for
food safety plans? How often does this occur and which aspects do inform audit
frequency and by whom these are undertaken?

a. the local government is to do everything in its power to:

i. assist the auditor to conduct an audit and carry out his or her other
duties under the Act; and  
ii. ensure that audits are conducted successfully and expeditiously;
b. a local government is to meet with its auditor at least once in every year;
c. a local government is to examine the report of the auditor and is to:

i. determine if any matters raised require action to be taken by the local

government; and
ii. ensure that appropriate action is taken in respect of those matters;
d. a local government is to:

i. prepare a report on any actions taken in respect of any matters raised

in the report of the auditor; and
ii. forward a copy of that report to the Minister by the end of the next
financial year, or six months after the last report prepared by the
auditor is received by the local government, whichever is the latest in
time.

Audits can be performed monthly, quarterly, twice a year, or once a year. It is

important to understand the criteria which should be considered before defining an
internal audit frequency, as not all processes should be considered on the same
timeline

18. What is the purpose of a first-party audit? How is it recognized in terms of

scheduled audit frequency?

 Identification of possible weaknesses in your quality management process

  Discovering any potential issues that could lead to non-compliance penalties
 Focusing attention on opportunities to eliminate waste in your processes
 Initiating corrective and preventive actions for any non-conformances
 Maintaining consistent adherence to quality controls and systems
A first-party audit is performed within an organization to measure its strengths and
weaknesses against its own procedures or methods and/or against external
standards adopted by (voluntary) or imposed on (mandatory) the organization. A
first-party audit is an internal audit conducted by auditors who are employed by the
organization being audited but who have no vested interest in the audit results of
the area being audited.

19. What is the purpose of food safety records during audits? What are the record

keeping requirements for food safety records and audit reports?

It is all well and good to have information written down, but if you cannot read it
or it is not legible it may cause some issues during the food certification audit
process. A food business should consider language used, the medium to which the
information is recorded for example paper, video or electronically and also the
ability for the information not to diminish or fade over time.

The record keeping requirements for food safety records and audit reports are:

 Who is responsible for a specific duty;

 How they are to perform the duty;
 When they are to perform the duty;
 Spaces for the date and initials of the person who is responsible for the
record(s); and
 Spaces for stating deviation findings and the actions taken to that fix that
issue.

20. A food safety program must include information about the review of the
program. Which details does this need to include?

 Provide for the regular review of the program by the food business to ensure
its adequacy.
 Identify all potential food safety hazards that may be reasonably expected
to occur in the food business’ operations
 Identify solutions for controlling these hazards
 Include daily records that demonstrate regular measurement and
observation for each of the controls
 Provide procedures for corrective action when a hazard is found to not be
under control

21. List three (3) types of records which must be kept by a business to demonstrate

action and compliance in relation to the food safety program

1. Employment records

In addition to the records required by the Australian Taxation Office (ATO) and

State and Commonwealth industrial laws (see Employment), associations may
wish to set up employment related record systems.

2. Safety records

The following health and safety records should be kept in a separate file for easy
access and reference:

 complaints;
 incidents;
 risk management analysis;
 training details;
 safety committee minutes; and
 copies of specific management committee resolutions.

3. Insurance records

Copies of all insurance policies should be kept in a secure place. Changes to

policies should be updated on the files immediately when they are received.

22. What are the legal requirements for food safety records to demonstrate that a
business is complying with the food safety program?

food safety law requires every food business operator (FBO) to carry out a
verifiable risk assessment of their own operation, identifying all potential food
safety risks and then taking steps to manage them. This approach, which focuses
on preventing food safety issues occurring rather than policing them after they
have happened, implicitly requires FBOs to keep records of the steps they are
taking to prove that they are in compliance with the law. The form and extent of
these records will, of course, depend on the operation in question. For example,
any food being held hot for serving must be kept above 63°C and, similarly, any
chilled food must be kept below 8°C.