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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.
5
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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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ROP in Food Establishments
Cook Chill Packaging Seal-a-Meal
machine
used to make
the hermetic
seal
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ROP in Food Establishments
Cook Chill Packaging
Rapid chilling
in a tote with
ice water
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ROP in Food Establishments
Cook Chill Packaging
Storage in the
walk-in cooler
at 38F
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ROP in Food Establishments
Cook Chill Packaging
Rethermalizing
or reheating
bagged
product in hotwater
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ROP in Food Establishments
Cook Chill Packaging
Tumble
Chiller to drop
product
temperaturerapidly
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ROP in Food Establishments
Cook Chill Packaging
Tumble chiller
cools 200+
bags (1 gal.)
to 39F in 1 hr.
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ROP in Food Establishments
Cook Chill Packaging
Cook Chill
Packaging
Labeling Bags
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ROP in Food Establishments
Cook Chill Packaging
Cook chill
packaging
warehouse
storage ofbagged
product at
29F
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ROP in Food Establishments
Vacuum Packaging
Vacuum
Packaging in a
Pouch Table
Top Machine
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ROP in Food Establishments
Vacuum Packaging
Vacuum
Packaging
Placing Filled
Pouch in theMachine
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ROP in Food Establishments
Vacuum Packaging
Vacuum
Packaging
Sealing the
Pouch
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ROP in Food Establishments
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
in Food Establishments
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
in Food Establishments
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
in Food Establishments
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?
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