Food safety management system Fast food restaurent


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how to design , plan and implementation Food Safety Management System

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Food safety management system Fast food restaurent

  2. 2. 2 | P a g e TABLE OF CONTENT. Sr.No. Content Page number 1 Summary of assignment 3 2. Planning and designing of food safety system 4 3. Step 1: Global standard procedure for food safety. 4 4. Step 2 :Pre requisites programs 4 Step 3: Senior management implementation. 6 Step 4: Food safety / HACCP implementation program. 7 Step 5:Food safety quality maintain documentation 8 Step 6:Training and implementation 9 Step 7:Internal auditing and checklists 10 5. Personal hygiene 10 6 Training 11 7 Facility design and layout Restaurant lay out Kitchen lay out. 15 8 Flow of food 17 9 Risk factors 18 10 Supplier selection program 18 11 Active managerial control 19 12 Sanitation program 20 13 PEST control system 20 14. References 22
  3. 3. 3 | P a g e SUMMARY OF ASSIGNMENT Our main objective behind preparing this report is to understand the food safety management system and create, design and prepare system in our concept restaurant that is fast food restaurant situated near Lucerne, Switzerland. Our system is based on planning, implementing and training our employee with documenting different check list and procedure. Food Safety management system includes following. Quality Management System which is an ideal for Food Issues for Food Safety Quality Management Systems.  Procedures Manual  Record Templates  HACCP Manual containing the HACCP Calculator  Standard for Food Safety Training Module  Global Standard for Food Safety Gap Analysis Checklist  Quality Manual PLANNING & DESIGNING OF SYSTEM. 7.Internal Auditing checklist 1.Global standard for food safety 2.Asessment of prerequisities 3.Senior Management Implementation. 4. Food safety/HACCP implementation . 5. Food safety quality managemme nt system 6.Training and implementation
  4. 4. 4 | P a g e Step One:Introduction to the Global Standard for Food Safety Comprehensive illustrated and interactive training module will introduce the Global Standard for Food Safety to the management team and explain how to start the process of implementing Food Safety Management includes following sections 1. Management commitment and continual improvement. 2. Food safety /HACCP plan. 3. Food safety & quality management system. 4. Site standard. 5. Product control. 6. Process control. 7. Personnel. Step Two: Assessment of Prerequisites At this stage an assessment should be made by the most senior technical member of the management team to decide if Site Prerequisite Standards within the facility meet the Food Safety Requirements in Sections 4 to 7 of the Standard. The nominated manager should read through the requirements in Section 4 to 7 of the Global Standard for Food Safety and assess for compliance using the checklist to record their findings.  Corrective Actions from Assessment of Prerequisites The non-compliances identified in the assessment of compliance with Sections 4 - 7 of the Global Standard for Food Safety 2008 should be logged using the form and used as input for Step Three: Senior Management Implementation. In Step 3 the appropriate corrective action should be allocated by the Senior Management Team and a corrective action plan formulated. Step Three: Senior Management Implementation A Senior Management Implementation checklist is provided that establishes your Food Safety Management System fundamentals including Food Safety Policies and Objectives. The checklist guides Senior Management:  in planning the establishment of the FSMS  In providing adequate support to establish the FSMS  in ensuring there is adequate infrastructure and work environment  in allocating responsibility and authority
  5. 5. 5 | P a g e This stage requires the Senior Management to meet and establish thefoundations for the Food Safety Management System:  Formulating a checklist of Customer, Regulatory, Statutory andother relevant Food Safety requirements  Decide which Food Safety requirements the company shouldaddress and develop relevant policies.  Based on the Food Safety Policy Management Policies establishFood Safety Objectives  Define the scope and boundaries of the FSMS  Plan the establishment of the FSMS using the project planner  Provide adequate support to establish the FSMS  Ensure there is adequate infrastructure and work environment anddevelop a Corrective Action Plan to rectify Prerequisite shortfalls  Allocate responsibility and authority  Assess, plan and establish appropriate internal and externalcommunication (including the food chain) channels As a decision has already been made to implement a system compliantwith the Global Standard for Food Safety, the Senior Managementmeeting should also consider the requirements of the Standard whichare summarized and should be read direct from the Standard:  Senior Management FSMS Implementation Checklist The Senior Management FSMS Implementation Meeting should follow the guidelines of the Senior Management Implementation Checklist.  Senior Management Establish the Project Plan Customer Communication Several streams of communication can occur with customers, including marketing, sales, development and technical. The Sales Director should agree new contracts in principle with current and potential customers. All new arrangements and products should then be subject to the approval procedure and must be officially approved by the Food Safety Team Leader who should ensure that this is effectively communicated and documented. All products are supplied to mutually agreed customer specifications which include information which is to be effectively communicated regarding:  allergen contents and warnings  intended use  nutritional contents  storage requirements  shelf life
  6. 6. 6 | P a g e The customer service/ front guest handling staff should be dealing with day to day enquiries and orders from customers. Customers requiring more technical information should be passed on to the Food Safety Team Leader. Non-Critical Quality complaints from customers should be directed to a responsible person such as the Customer Services Manager who should co-ordinates the customer response. Critical or Serious complaints such as a claim of alleged injury or poisoning should be notified to the Food Safety Team Leader who will instigate an immediate investigation and co-ordinate the appropriate response.  Food Authority Communication The Food Safety Team Leader should retain responsibility and authority for external communication and liaison with food authorities and any other organizations that may have an impact on the Food Safety Quality Management System. Step Four: Food Safety Plan/HACCP Implementation HACCP Training, an interactive and illustrated HACCP training presentation is supplied to train your food safety team in the preliminary steps to a Hazard analysis, the principles of HACCP and how to utilize the HACCP calculator in implementing your HACCP system. HACCP Implementation Tasks HACCP Implementation Tasks are to be completed by the Food Safety Team using the guidelines included in this HACCP Implementation Section. We will go through the task by section as the requirements per Global Standard for Food Safety: Prerequisite programs are established including:  Cleaning and sanitizing  Pest control  Maintenance programs for equipment and buildings  Personal hygiene requirements  Staff training  Purchasing  Transportation arrangements  Processes to prevent cross contamination  Allergen controls
  7. 7. 7 | P a g e Design of the HACCP Plan The Food Safety Team need to formulate and document a HACCP plan defining the hazards to be controlled, CCPs where hazards are controlled, critical limits and monitoring procedures at each CCP and action to be taken when critical limits are exceeded. The HACCP plan needs to define those responsible for performing monitoring procedures and the records where the monitoring results are recorded. The food safety team identifies critical control points (CCP) s for each food safety hazard Critical Control Points are established using the decision tree as the latest step in the flow path where controls can be effectively administered for a particular Significant Food Safety Hazards. Step Five: Food Safety Quality Management System (CERTIFIED /QUALIFIED EMPLOYEE PORTAL) Our Food Safety Management System contains a comprehensive compliant documentation. Certification tools you will find:  Food Safety Quality Manual containing a set comprehensive procedures and an extensive range of record templates.  HACCP manual containing food safety procedures and our unique HACCP Calculator.  Laboratory manual including sample procedures and records.  At this stage you can choose to totally implement the procedures supplied or pick those that are applicable to your process.  The Food Safety Quality Manual contains comprehensive top level procedures templates that form the foundations of your Food Safety  Management System so you don't have to spend 1,000's of hours writing compliant procedures Documentation: -Food Safety Management System Record Templates A comprehensive range of easy to use food safety management systemrecord templates: 1. Management Review Minutes 2. Training Record 3. Product Release Record 4. Design and Development Records 5. Supplier Assessment Record 6. Validation Record 7. Identification and Traceability Record 8. Register of Customer Property 9. Calibration Record 1. Records of Non-conforming Product 2. Corrective Action Request Form 3. Preventative Action Request Form 4. Supplier Self-Assessment and Approval Form 5. Equipment Commissioning Record 6. Return to Work Form 7. Hygiene Policy Staff Training Record
  8. 8. 8 | P a g e 8. Complaint Investigation Form 9. Prerequisite Audit Checklist 10. Knife Control Record 11. Knife Breakage Report 12. Goods in Inspection Record 13. Equipment Cleaning Procedure 14. Glass and Brittle Plastic Breakage Record 15. Metal Detection Record 16. First Aid Dressing Issue Record 17. Cleaning Schedule 18. Cleaning Record 19. Engineering Hygiene Clearance Record 20. Glass and Brittle Plastic Register 21. GMP Audit Checklist 22. Vehicle Hygiene Inspection Record 23. Outgoing Vehicle Inspection Record 24. Pre-Employment Medical Questionnaire 25. Visitor Questionnaire 26. Product Recall Record 27. Shelf Life Confirmation Record 28. Accelerated Keeping Quality Log 29. Goods In QA Clearance Label 30. Maintenance Work Hygiene Clearance Form 31. Changing Room Cleaning Record 32. Color Coding Red Process Areas 33. Daily Cleaning Record for Toilets & Changing Rooms 34. Drain Cleaning Procedure Filler Areas 35. General Cleaning Procedure 36. Product QA Clearance Label 37. CIP Programme Log 38. Sample Filler Cleaning Record 39. Pipe Diameter Flow Rate Conversion Table 40. QC Online Check Sheet Step Six: Training and Implementation A significant part of the implementation process is training. JobDescriptions should be available for all staff and they should be briefedand aware of their food safety responsibilities.For each employee and individual training record should be completed. Basic Training should be given to all staff and also include:  Job/Task Performance  Company Safety and Quality Policies and Procedures  Good Manufacturing Practices  Cleaning Procedures
  9. 9. 9 | P a g e  HACCP  Bio security and Food Defense.  Product Quality  Chemical Control  Hazard Communication  Blood borne Pathogen  Emergency Preparedness  Employee Safety  Safety Regulatory Requirements/Quality Regulatory Requirements The Food Safety Team should receive extra training:  Internal Audit Training (Conducted in Step Seven)  HACCP Training Remember all food handlers should receive Basic Food Hygiene Training. We have design the web portal for our employee, who can login to portal and read document and give examination online, that will give them extra earning incentive per exam and per phase they pass as training certification in our our all employee should have to pass the basic training online within three month of employment date. Moreover extra earning incentive and promotion certification is also available on our portal. Step Seven: Internal Auditing Training & Checklists Internal Auditor Training - An interactive and illustrated Internal Audittraining presentation to train your Internal Audit procedure.Internal Audit Checklists are supplied to cover all the sections of thestandard.
  10. 10. 10 | P a g e Procedures and checklist details. 1. Personal Hygiene 2. Training 3. Facility Design 4. Flow of Foods 5. Risk Factors 6. Supplier Selection (Procedure) 7. Active managerial control 8. Sanitation Program 9. Pest Control Personal hygiene procedure. Observe Good Hygienic Practices!  Wash hands only in the hand sink – not in the dishwashing, food prep or mopSinks!  Ill employees can cause foodborne Illness. Enforce sick leave policy or reassignDuties.  Do NOT eat, drink, use toothpicks or any form of tobacco in food-production areas.  Do NOT use a common cloth towel or apron for hand wiping.  NO bare hand contact with ready-to-eat food!  Wear nails short, clean and unpolished. Restrict rings to plain bands. If wearing artificial fingernails, wear gloves when handling food.  Cover open cuts and burns with bandages or single-use gloves. Use single-use gloves with finger cots. STOP Disease Outbreaks 1. Use warm water 2. Wet hands and exposed arms up to the elbow 3. Apply hand soap 4. Rub hands and forearms briskly for 20 seconds 5. Rinse under warm water 6. Towel dries with disposable towels. When to wash your hands • Before starting work • Before putting on gloves • After using the restroom • After touching your hair, face, or body
  11. 11. 11 | P a g e • After eating, drinking, smoking, or touchingchewing gum • Upon entering a food preparea • After working with raw food • After cleaning or taking outgarbage • After touching anything thatcontaminates the hands CAUTIONS!!!!! Let your supervisor know immediately if you have any of these symptoms! Restrict from working with food or food contact surfaces: • Sore Throat with Fever • Open cuts or infected wounds • Contact with anyone who has Salmonella typhi, E. coli 0157:H7, Hepatitis A, or Shigella. Exclude employees from the food establishment diagnosed with: • Salmonella • Shigella • E. coli 0157:H7 • Hepatitis A Or with symptoms of: • Norovirus • Diarrhea • Vomiting • Jaundice Supervisors: if an employee has been diagnosed with one of the above illnesses, or is jaundiced you must notify ADEC within 24 hours. Training procedure Step 1: - interview New hiring employee has self-assessment sheet that has to attend during the employee interview that include the basic knowledge of trainee or employee for hygiene, food borne illness and its risk. Step 2: induction and orientation
  12. 12. 12 | P a g e In this phase each employee has given a hand book to read and instruction by superior employee to new trainee for maintaining hygiene and how to follow procedure and rules. Moreover few days of shadowing would be fine if necessary for trainee. Step 3:- incentive and promotion on portal. We have our own restaurant portal on which different documentation would be uploaded for HACCP , other safety measure , precaution , procedure ,rules , food borne illness once employee hired they has to pass the basic examination within 3 months of time period. This programme will add incentive to their salary and give chance to promote themselves. Step 4:- Employee hand out We provide employee hand out to each employee of our restaurant that include the basic rule of hygiene and safety, moreover we correct the behavior of employee once and after training by constant watching and documenting it. Facility design Facility design includes the • Equipment • Maintenance • Purchasing • Warehousing • Communications • Transportation • Waste management • Computer systems Warehouse/Storage ♦ Freezers and refrigerators ♦ Hoists/lifts ♦ Forklifts, pallet jacks ♦ Scales Ingredient Control ♦ Scales of varying capacities Hot Food Production ♦ Can opener with automatic dumping ♦ Steam-jacketed kettles ♦ Pumps/fillers ♦ Blast or tumble chiller Cold Food Production ♦ Slicers with automated weighing
  13. 13. 13 | P a g e ♦ Vertical cutter mixers ♦ Wrappers Bakery ♦ Mixers ♦ Proofers ♦ Ovens ♦ Depositors Assembly/Packaging ♦ Conveyor ♦ Fillers ♦ Packaging/wrappers ♦ Meal baskets and dollies Sanitation ♦ 3-compartment sinks ♦ Dishwashing machine. The size and type depend on decisions about whatdishwashing is done at the central kitchen or at the satellites. The use ofDisposables also impact the dishwashing equipment required. ♦ Cart washers
  14. 14. 14 | P a g e Restaurant layout.
  15. 15. 15 | P a g e Kitchen area
  16. 16. 16 | P a g e Flow of food guideline Cook to this temperature or hotter:  Eggs 145° F  Fish 145° F  Ground beef 155° F  Pork 155° F  Poultry 165° F  Stuffed Meat 165° F  Traditional Wild Game Meat 165° F Microwave Cooking: • Cover and cook (stir or rotate) to 165°F or hotter - then letfood stand (with cover on) for 2 minutes. Cold Holding • Keep food at 41°F or colder at all times. • Discard food that has been held between 41-135°F for longer than 4 hours. • Cover foods to maintain temperature. Hot Holding • Keep food at 135°F or hotter. • Preheat equipment to 135°F or hotter before adding food. • Check food temperatures with a thermometer. • Stir frequently to evenly distribute the temperature. Use a thermometer to check that foods are cooled: • From 135° F to 70° F within 2 hours; then • From 70° F to 41° F within 4 more hours. • Pre-chill salad ingredients (such as tuna, mayonnaise, etc.) OR cool from roomtemperature to 41° F within 4 hours. Methods: Reduce the size of poultry, fish and meat roasts Shallow pans (soups, sauces, gravies, etc.): 1. Put a 2-inch layer of food in a shallow pan. 2. Do not cover. 3. Put the pan in the cooler where cold air can blow across it. 4. Stir to help release heat. 5. Cover the food after it has cooled.
  17. 17. 17 | P a g e 6. Can also be used for small to medium sized pieces of meat. Ice bath: 1. Put the food container into an ice water bath. 2. Stir the food every 30 minutes - more often if possible. Chilling wands or paddles (for large containers): 1. Place the clean, frozen wand in the food and stir. 2. May be used in combination with another rapid cooling method -such as ice bath, or pouring into shallow pans to finish. Adding ice instead of water (soups, stews, etc.): 1. Add only half of the water before cooking. 2. After cooking, add the other half as ice. Hot foods above 140°F - Cold foods below 41°F 1. Take food temperatures every 2 – 3 hours. If food is in the temperature DANGER ZONE, take corrective action: - Reheat, - Quick chill, or - Discard 2. Stir food frequently to distribute the temperature. 3. Do not add fresh food to old – “first in, first out”. 4. Trained workers must monitor self-service food bars. 5. Require customers to use clean plates and bowls for return trips to the food bar. 6. Protect foods from contamination by providing properutensils and sneeze guards. Inspect food as soon as possible after receiving.  Accept food only if: o It is from an approved source. o It is in wholesome condition. o Containers and packaging are not contaminated or damaged in a manner to allow contamination of food. o Potentially hazardous cold foods are less than 41°F, and potentially hazardous hot foods are greater than 140°F. o Shell eggs are clean and unbroken. o Frozen food has no visible signs of thawing or refreezing. o Raw or raw frozen shellfish/meat containers are properly labeled with species, quantity, and harvest site, date of harvest, name and certification number of the harvester/original shipper.  Store foods properly and as soon as possible.
  18. 18. 18 | P a g e o Protect ready-to-eat foods from raw foods and store them separately. Separate raw meat, fish and poultry. Store raw foods under ready-to-eat foods Temperature: • Rapidly reheat food to 165°F or hotter. • Stir food frequently todistribute the heat. • Use a thermometer to verifythe temperature. Time: • Heat to 165°F in 2 hour or less. Reheating equipment: • Stove top, steam cooker, microwave, and ovens. Hot holding equipment: • Preheat to 140°F or hotter before adding food. • Do not use hot holding equipment to reheat food. Risk Factors Cross contamination  Transferring germs from soiled hands, utensils, or equipment to clean equipment, or to food that will not receive additional cooking.  EXAMPLE: You used a knife to cut up raw chicken then used the same knife to cut up salad ingredients. Cutting boards and prep tables:  Wash, rinse, and sanitize between raw and ready-to-eat  (RTE) food and between different types of raw meat, fish, and poultry.  Keep cutting boards and prep tables easy to clean by replacing as needed. Hands:  When handling ready-to-eat (RTE) food, use utensils or gloves.  Wash hands often and always between tasks. Storage:  Store raw meat, fish, and poultry below RTE.  Keep food that does not require further washing or cooking separate from food that does.
  19. 19. 19 | P a g e Supplier Selection (Procedure)  Keep records of your suppliers and know their facilitylocation, contact persons and phone numbers.  Keep records of product information, inventory anddeliveries.  ALWAYS read communications from your supplier.  Recallinstructions may be verified with the Food Safety andSanitation Program  Separate the recalled food products to be returned to thesupplier from your inventory immediately.  Keep a record of the products returned to the supplier. Thisshould include product name, manufacturer, code numbersand/or date of manufacturing. Active managerial control Active Managerial Control "as the purposeful incorporation of specific actions or procedures by management into the operations of business to attain control of the foodborne illness risk factors." It is taking actions that will prevent a foodborne illness by following record management and procedure in restaurant.  Knowing when to restrict or exclude an ill employee, immediate report to the supervisor if ill employee on work, it will be under supervision and if necessary on one or two day leave.  Having knowledgeable, well-trained staff: - we have different level of training on our restaurant for employee and we reward our employee with incentive with training completion & certification.  Having a pro-active approach to identify, evaluate and control food safety hazards. It is include all procedure and standard we have to document and maintain quality and correct any measure if necessary.  Having Standard Operating Procedures: - we have design the procedure what to do and do not do.  Knowing corrective actions: before it’s too late and we lose our customer and harm our business we take corrective action if any situation occur.  Keeping records and monitoring food quality and individuals handling food.
  20. 20. 20 | P a g e Sanitization procedure. What to use and how to use it. Bleach Solution 1. 1 teaspoon of unscentedhousehold bleach per gallonof water. 2. Use chlorine test strips tocheck the concentration. 3. Aim for 100 ppm. Quaternary Ammonia (Quat) 1. Read label directions orcheck with your supplier. 2. Use Quat test strips to checkthe concentration. 3. Aim for 200 - 400 ppm. How to Use a Sanitizer: In a labeled spray bottle: 1. Spray, wait 30 seconds, wipewith a clean paper towel. 2. Make fresh sanitizer at leastonce a day. In a bucket: 1. Keep a clean wiping cloth inthe solution. 2. Wring out the cloth and wipedown the clean surface. 3. Let the surface air dry. 4. Use one bucket for foodcontactsurfaces and another for non-food contact surfaces. Label the buckets. 5. Make a new sanitizer often – adirty sanitizer doesn't killgerms. INTEGRATED PEST control programme and procedure. How to perform task!!!  If the pests don't live close by there's less chance they'll enter your facility. Make sure all areas close to buildings are paved or made of materials that pests do not want live in, e.g. not plants/soil.  Arrange for rubbish bins stored outside to be emptied regularly so they are not an attractant to pests.  Use external rubbish bins that are enclosed so it's harder for pests to access them.  Do not feed any stray animals (e.g. cats, dogs and birds) found in the vicinity of the building.
  21. 21. 21 | P a g e  Locate your building away from other businesses/buildings that may attract pest or have poor pest management.  Ensure the facility is not close to water sources (e.g. streams and lakes) that may attract pests.  Stop water taps on the outside of your building from dripping to take away a potential source of drinking water for pests.  Clean up any spills of food items as soon as they happen.  For dry materials use a small brush and shovel and transfer the material directly into a rubbish bin.  For wet materials push the spilled food item towards a floor drain usinga broom/squeegee.  If there are no floor drains use paper towels to soakup the spill and put the towels directly into a rubbish bin.  Follow upusing a mop and bucket.  Clean dry areas daily using a vacuum cleaner (with a sealed bag so it does spread dust).  Make sure regularly move all the pallets in and clean underneath.  procedures explaining such things as; 1) How traps should be checked for insect activity 2) How to add fresh bait to traps 3) How to clean/empty equipment used to electrocute flying insects. 4) How to operate equipment use to "fog" to kill stored insects  Pest control procedures include information about safetyHandle chemicals. This includes wearing gloves/masks and washingHands afterwards. WASTE MANAGEMENT  Waste bins, tubs and dumpsters used in the collection, holding and storage of waste materials require proper cleaning and sanitizing to minimize the potential attraction and support of food pests.  Waste must not be allowed to accumulate in food handling, food storage, and other working areas and the adjoining environment.  Waste stores must be kept appropriately clean ERADICATION  Pest infestations should be dealt with immediately Treatment with chemical, physical or biological agents should be carried out without posing a threat to the safety or suitability of food. ==============================================================================
  22. 22. 22 | P a g e References  Agency, F.Food Standards Agency - Introduction to HACCPIn-text: (Agency, 2014) Agency, F. 2014. - Introduction to HACCP. [online] Available at: industry/caterers/haccp/#.Uxyo6PldVic [Accessed: 9 Mar 2014].  ANAB Accreditation for Food Safety Management Systems In-text: (, 2014) 2014. ANAB Accreditation for Food Safety Management Systems. [online] Available at: [Accessed: 9 Mar 2014].  Wikipedia.ISO22000 In-text: (Wikipedia, 2014) Wikipedia. 2014. ISO 22000. [online] Available at: [Accessed: 9 Mar 2014]  22000:2005 - Food safety management systems -- Requirements for any organization in the food chain In-text: (, 2013) 2013. ISO 22000:2005 - Food safety management systems -- Requirements for any organization in the food chain. [online] Available at: [Accessed: 9 Mar 2014].  Food Safety Management System In-text: (, 2014) 2014. Food Safety Management System. [online] Available at: Http:// [Accessed: 9 Mar 2014].  Anonymous. In-text: (Anonymous, 2014) Bibliography: Anonymous. 2014. [online] Available at: [Accessed: 9 Mar 2014].  In-text: (Anonymous, 2014)Bibliography: Anonymous. 2014. [online] Available at: nts%20for%20an%20HACCP.pdf [Accessed: 9 Mar 2014].  Food Safety Management Programs: Applications, Best Practices and Compliance -- Complimentary SafetyChain Webinar March 4 | SYS-CON MEDIA In-text: (, 2014) Sys- 2014. Food Safety Management Programs: Applications, Best Practices and Compliance - - Complimentary SafetyChain Webinar March 4 | SYS-CON MEDIA. [online] Available at: [Accessed: 9 Mar 2014].