Cooking - ROP

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COOKING

Its purpose is to make foods more

palatable by changing its

appearance, texture and aroma.

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Cooking Guidelines for PHF :

Reheat all leftover foods to 1650F ( 15

sec.).

Cook pork, pork products and ground beef

to 1650F in 15 sec.

Cook poultry to 1800F

Cook fish to 1400

F Keep the internal temperatures for roast

beef, fish and eggs for 15 sec.

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Hold all PHF at 1400F or above. Cool

quickly to 700F in two hours and from 70-400F in four hours.

Hold cold PHF at 400F or below

The easiest rule to remember is:

KEEP HOT FOOD HOT AND COLDFOOD, COLD.

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COOLING

Approved cooling methods:

1. stirring

2. transfer in smaller container3. use stainless steel

4. ice water bath

5. cooling paddles

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REHEATING

All PHF meant to be held hot

must be reheated to at least

1650F within 2 hours.

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SERVING

Practice good personal hygiene

Hold utensils only by the handles,

bottom or outer rim of plates

Never dry hands on the apron

Use dingle service towels

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What is Reduced Oxygen Packaging

and What are the Food Safety

Concerns & Controls?


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Reduced Oxygen Packaging

Considerations:

What is ROP

Benefits and concerns for ROP

Microbiology & pathogens of concern for ROP

Gases associated with ROP and their uses

ROP packaging materials & equipment

Barriers, hurdles & controls for pathogens

How to conduct an ROP inspection


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ROP Changes in the

2005 Food CodeReduced Oxygen Packaging means:

(i) The reduction of the amount of oxygen in apackage by removing oxygen; displacingoxygen and replacing it with another gas or

combination of gases; or otherwise controllingthe oxygen content to a level below thatnormally found in the surrounding, 21%oxygen atmosphere, and

(ii) A process that involves a food for which thehazards ofClostr id ium bo tu l inumandLister ia monocytogenesrequire control inthe final packaged form.


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ROP Changes in the

2005 Food CodeVacuum packaging, in which air is removedfrom a package of food and the package ishermetically sealed so that a vacuum remainsinside the package,

Modified atmosphere packaging, includes:reduction in the proportion of oxygen, totalreplacement of oxygen, or an increase in the

proportion of other gases such as carbondioxide or nitrogen; and


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ROP Changes in the

2005 Food Code

Controlled atmosphere packaging, in whichthe atmosphere of a package of food is modified

so that until the package is opened, itscomposition is different from air, and continuouscontrol of that atmosphere is maintained, suchas by using oxygen scavengers or a

combination of total replacement of oxygen,non-respiring food, and impermeable packagingmaterial.


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ROP Changes in the

2005 Food CodeCook chill packaging, in which cooked food is hot filledinto impermeable bags which have the air expelled andare then sealed or crimped closed. The bagged food israpidly chilled and refrigerated at temperatures that

inhibit the growth of psychrotrophic pathogens. (new)

Sous vide packaging, in which raw or partiallycooked food is placed in a hermetically sealed,

impermeable bag, cooked in the bag, rapidlychilled and refrigerated at temperatures thatinhibit the growth of psychrotrophic pathogens.(new)


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Benefits of ROP

Extends shelf life of packaged food

Reduces need for skilled labor

Provides more consistent quality Takes less time for preparation

Results in less mess, fewer dirty utensils

Takes less time to prepare Portion control problem eliminated


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Concerns about ROP

Facultative bacteria (most foodborne pathogens) growunder aerobic & anaerobic conditions

Most spoilage organisms are no longer indicators fortemperature abuse

Extended shelf life could allow slow growers to reachhigh numbers under refrigerated conditions

Secondary barriers such as low pH or aw are not alwayspossible with cook chill and sous vide packaging

Potential for temperature abuse at retail and in the home

is great Cooking and fermentation destroy most vegetative cells

but spore formers survive


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General Controls for ROP Hazards

Additional controls built into the Code:

Minimize bacterial load with HACCP & SSOPs

Use the hurdles or barrier concept with refrigeration

Store cook chill and sous vide products at 34F if noother hurdles are present

Cannot sell cook chill or sous vide bagged product to

customers

ROP fish only if frozen before, during and after ROP Place 14 or 30 day use by dates on labels to limit

shelf life


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ROP Pathogens of Concern

Why is Listeria monocytogenesa concern in ROP? Conditions for LM growth:

10 % salt

5-10 % O2

pH 4.1 9.6

aw 0.90 - 0.93

28F - 122F

LM can survive months in a moist environment - steam fromcooking, dishwashing machines, pressure sprayers.

LM competes well with other organisms, especially at

refrigeration temperatures LM is more heat resistant than most vegetative pathogens

a concern with lightly cooked foods


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Gas Component(s) of ROP

Normal atmosphere 21% O2, 0.03% CO2,

(remainder is N2, trace gases, water vapor)

Back flushing with CO2, N2, O2, CO

CO2 is antimicrobial, 5-10% inhibits spoilageorganisms, anaerobes unaffected

O2 speeds growth, ripening, aging, inhibits

anaerobes, is necessary for spoilage indicators

N2 is inert, a filler gas, decreases rancidity

CO protects color, is GRAS, no labeling required, no

CO remains after opening package


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ROP Absorbents & Packaging

Absorbents (Scavengers)

Easily oxidizable compound, used in CAP

Absorbs O2, ethylene, moisture, etc.

Contained in sachet, label or packaging materials Packaging

Non-transmissible to O2

(at 10-100 cc O2/m2/24hrs)

Hermetic seal

Layered for different properties (strength, flexibility,

moisture control, etc.)


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ROP in Food Establishments

Cook Chill Packaging

Hot filling

bags by hand


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Cook Chill Packaging Seal-a-Meal

machine

used to make

the hermetic

seal


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Rapid chilling

in a tote with

ice water


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Storage in the

walk-in cooler

at 38F


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Rethermalizing

or reheating

bagged

product in hotwater


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Tumble

Chiller to drop

product

temperaturerapidly


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Tumble chiller

cools 200+

bags (1 gal.)

to 39F in 1 hr.


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Cook Chill

Packaging

Labeling Bags


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Cook chill

packaging

warehouse

storage ofbagged

product at

29F


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Vacuum Packaging

Vacuum

Packaging in a

Pouch Table

Top Machine


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Vacuum Packaging

Vacuum

Packaging

Placing Filled

Pouch in theMachine


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Vacuum Packaging

Vacuum

Packaging

Sealing the

Pouch


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Vacuum Packaging

Vacuum

packaged fish

must be frozen

before, duringand after

vacuum

packaging


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ROP Controls

in Food Establishments Secondary barriers or hurdles with refrigeration

at 41F (Hurdle Effect) pH or acidity 4.6

Natural

Acidification Fermentation

Water activity (aw) 0.91 Dried products (jerky, dry fermented sausage)

High salt or sugar concentration

Cured meat or poultry products Salt added at 3.5% Nitrite (inhibits spore germination and toxin production

byClostr id ium botu l inum )


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ROP Controls

in Food Establishments

Freezing (required for fish)

Surveillance sampling showed 21.7 - 66.7%of fish samples are contaminated with

Clost r id ium botu l inum(A, B, E or F) Normal spoilage tells consumers not to eat

product (too old, temperature abused, etc.),BUT

MAP modifies spoilage conditions to allowClost r id ium botu l inumto grow and producetoxin before signs of spoilage occur.


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ROP Controls


Live competing organisms

Spoilage organisms

grow faster than pathogens

out compete for nutrients

Fermentation by lactic acid bacteria

Metabolic products inhibit

Starter cultures give jump start Effective against E. co li, Salmonel la, Clostr id ium

bo tul inum , Lister ia, Staphy lococ cus aureus


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ROP Controls

in Food Establishments Intrinsic factors present in certain cheeses (hard,

semi-soft and pasteurized process cheese) Lowered pH

Organic acids

Hydrogen peroxide

Natural antibiotics or bacteriosins (nisin) Salt (added during processing)

Lower water activity

Added preservatives (pasteurized process cheese)

Live competing cultures

Low redox potential (Eh) Extrinsic factors (certain cheeses)

Temperature at 41F or less

ROP including VP, MAP


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ROP Controls


Cook Chill/Sous Vide products must remain

under control of Food Establishment

Used On the premises

Satellite operations owned solely by operator Why home storage temperatures are in doubt

Audits International data

25% of home refrigerators are above 45 0 F

10% are above 50F

Van Garde & Woodburne

27% of home refrigerators are above 50


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ROP Controls

in Food Establishments Written HACCP plan and SSOPs (prior approval not

required) HACCP plan

Hazards (both Clostr id ium botul inumand Lister iamonocy togenesmust be considered)

Critical control points (refrigeration & secondary barrier) Critical limits 41F , secondary barrier and 14 day shelf life

34F, no secondary barrier and 30 day shelf life

38F, no secondary barrier and 72 hr. shelf life (2006 CFP) Monitoring (temperature continuously electronically

monitored)

Corrective actions (appropriate for safety) Verification (if unable to verify, must discard)

Record keeping (held 6 months for CC & SV records forcooking, cooling, refrigeration)


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ROP Control


Standard Sanitary Operating Procedures Training for food employees engaged in ROP is

critical and must identify: Procedures which must be followed

Critical limits which must be met, monitored, havecorrective actions if not met and record keeping

Consequences of not meeting critical limits

SSOPs (especially hand washing, no bare hand contactwith ready-to-eat foods, cleaning and sanitizing food

contact equipment) Dedicated work areas to separate raw and RTE foods

Handwashing & no bare hand contact with RTE foods


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ROP Controls

for Cook Chill & Sous Vide Cook chill and sous vide packaging require NO

VARIANCE, provided Food Code criteria are met in 3-502.12(D): (new) Implementation of a HACCP plan

Prepared and consumed on the premises or in a satellite

operation within the same business entity no direct sale ofbagged product to the public or another business

Cooked to the required temperature for that food

Protected from contamination.

Placed in an oxygen barrier bag just after or just prior tocooking and sealed

Cooled to 41F according to time and temperaturerequirements, then cooled to 34F within 48 hrs.

Can be removed to a 41F cooler for no more than 3 days, or

Can be held for 72 hrs at 38F after packaging (2006 CFP)


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ROP Controls

for Cook Chill & Sous Vide

Cook chill and sous vide packaging requiresNO variance, provided Food Code criteria aremet in 3-501.12(D) - contd: (New) Refrigeration units must be continuously monitored

electronically and visually examined twice daily using,for example:

Thermocouple data loggers

Recording charts

Temperature monitor & alarm systems to activate analarm or dialer

(Nickel-sized) data loggers with software to displaytemperatures


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ROP Controls in e Food Code

for Cook Chill and Sous Vide Cook chill and sous vide packaging requires NO

variance, provided Food Code criteria are met in 3-501.12(D)contd: (New) Bagged product transported to a satellite location must

have temperature monitored using verifiable electronic

monitoring Maximum shelf life at 34F (if not frozen) is 30 days after

preparation

Bags must be labeled with product name and date packaged

Cooling and refrigeration temperature records must be held6 months and made available to the regulatory authority

Any change in the cook chill or sous vide operation thatvaries from the criteria provided in 3-501.12(D) willrequire variance approval by the regulatory authority

O C f


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ROP Controls for

Vacuum Packaging Cheese Specific criteria to vacuum package certain cheeses are found in 3-

502.12(E) in the Food Code: (New)

Only cheeses that meet the Standard of Identity for hard cheeses(21 CFR 133.150), semi-soft cheeses (21 CFR 133.187) andpasteurized process cheeses (21 CFR 133.169) may be vacuumpackaged in food establishments without a variance.

Soft cheeses such as Brie, Camembert, Ricotta, Cottage andTeleme MAY NOT be vacuum packaged in a food establishment

A HACCP plan and SSOPs identified in 3-502.12(B) must beimplemented

Label must bear a use by date that does not exceed 30 days orthe original manufacturers sell by or use by date

Any cheese packages that are not consumed or sold within 30days must be discarded


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Facility Inspection of ROP Process

Storage & display of product for sale or use Appropriate storage temperature (41F, 38F or 34F)

No packages held past appropriate shelf life Examine expiration dates on packages in storage and on

display Discarded if beyond the appropriate expiration date

Continuous electronic monitoring for CC/SV Records kept 6 months for electronic monitoring

Visually examined twice daily (when? Who?)

No CC/SV product sold to another business entityor to the public in bagged/packaged form


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Facility Inspection for ROP Process

Records Review Pick 3-4 packages from storage or display

Choose different lots or expiration dates, ifpossible

Is the required information on the label?

Are corresponding records available for each lot?

Has all the information required by the HACCPplan been recorded on the log sheet or on the

computer records? Were there any instances that corrective action

was required? Was the corrective action done?

Cooking - ROP

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