Flow of Food Basics
The cycle foods travel is called the Flow of Food, and foods must be kept safe at each step. The steps are: purchasing, receiving, storing, preparation, cooking, holding, cooling, reheating, and serving.
Hazards
It’s the manager’s job to monitor foods along the flow of food, and to know how foods might become unsafe at any step. For example, the freezer truck that delivered your food might not have been cold enough. The manager must be able to spot signs of temperature abuse at the receiving step and reject unsafe food. A server might come to work sick, risking cross-contamination at the serving step. A certified manager must understand these concepts.
Cross-Contamination
Pathogens are easily passed from staff, surfaces, equipment, utensils, etc. and cross-contamination can happen at any step in the flow of food. Managers must know where and how cross-contamination can happen, and how to prevent it. Like keeping raw and RTE foods apart, using separate equipment and prep times, cleaning well and often, and buying foods that don’t require prep (e.g., pre-shredded lettuce).
Time-Temperature Control
Time-temperature abuse causes most foodborne illnesses. Any time food is in the Temperature Danger Zone (TDZ) (41°F to 135°F) and spends too long in or around 70°F to 125°F, it is at risk for rapid pathogen growth. To prevent time-temperature abuse, foods must be cooked to the proper internal temperature, held at the proper temperature, and cooled/reheated properly.
Time and Temperature Monitoring
Time-temperature abuse must be monitored along the flow of food to prevent harmful pathogen growth with the correct thermometer for the job, and all data monitored should be recorded. Procedures should be in place for minimizing TCS food’s time in the TDZ, and for corrective action to take place in case procedures aren’t met.
Types of Thermometers
The most important tool in monitoring foods is the thermometer. There are bimetallic stemmed thermometers, thermocouples, and thermistors.
Bimetallic Stemmed Thermometer
The best for monitoring foods along the flow of food, these range from 0°F to 220°F and must be inserted up to the dimple in the stem. They can be adjusted via the calibration nut and are easy to read and use.
Thermocouples and Thermistors
These take temperature via a metal probe with a sensor on the tip and have a digital display. They don’t have to be inserted as deep as bimetallic stemmed thermometers, making them appropriate to use for thin foods.
Infrared Thermometers (Laser)
These take the temperature of surfaces and don’t have to touch the surface in order to get a reading, minimizing risk of cross-contamination. But they cannot measure air or internal temperature.
Other Temperature Devices
Maximum registering thermometers can be used for long-term monitoring of temperature or to show temps inside dish machines. Time-temperature indicators can be attached to packaging, and their color change indicator shows if the food has been temperature abused in transit. Some companies also use temperature-recording devices in their delivery trucks that can be checked during receiving.
Using Thermometers
A manager must know how to properly use the thermometers in their facility, as well as how to care for them using the guidelines below and the manufacturer’s instructions.
Cleaning
Wash, rinse, sanitize (with food contact surface safe sanitizer), and air dry all thermometers before and after use, and keep them in their storage case.
Calibration
Calibrate thermometers often and any time they’ve been: dropped or bumped, exposed to extreme temperature changes, before deliveries, and before each shift. Some thermometers can’t be calibrated in-house and must be replaced or sent to the manufacturer for calibration. Always follow the manufacturer’s details for calibration.
Calibrate using the boiling-point method by placing the thermometer in boiling water and adjust it to 212°F, or using the ice-point method by placing it in ice water and adjusting it to 32°F. The ice-point method is fastest, easiest, and safest.
Accuracy
If used to monitor food, thermometers must be accurate within plus/minus two degrees Fahrenheit or plus/minus one degree Celsius. Thermometers used to measure air temperature for food storage (a hanging thermometer in the walk-in cooler) must be accurate within plus/minus three degrees Fahrenheit or plus/minus one and a half degrees Celsius.
Glass Thermometers
Glass thermometers, like candy thermometers, become a physical contaminant if broken. Only use glass thermometers enclosed in a shatterproof casing.
Procedure for Use
Before use, wash, rinse, sanitize and air dry the thermometer. Insert the thermometer probe into the thickest part of food (usually the center) when checking for internal temperature. Wait for the reading to steady for 15 seconds. Take a second reading in a different place to be sure.
The Purchase, Receipt, and Storage of Food
The flow of food begins with purchasing, then receiving and storing food. Once food becomes unsafe at one of these steps, it cannot be saved, so food must be purchased from reliable sources, received safely, and stored properly.
Food Purchasing
Purchase food from approved and reliable purveyors who’ve been inspected (including growers, shippers, packers, manufacturers, distributors, and markets). Know your purveyor’s safety procedures. Review USDA or FDA inspection reports of the purveyor’s receiving, storage, processing, shipping, cleaning, sanitizing, staff hygiene, training, recall program, and food safety system (HACCP). Deliveries should arrive when staff have enough time to inspect properly. If not, reschedule.
Receiving Food
Train specific staff to receive and inspect properly, using thermometers, scales, and purchase orders, and make sure they’re present when deliveries arrive. Inspections should begin immediately upon delivery. Staff should note signs of contamination and reject any problem packages, accepting only items at their correct temperature. Move cold and frozen items into storage as soon as possible.
Key Drop Deliveries
Deliveries from trusted, approved suppliers may be received after hours. Products should be placed in coolers, freezers, and designated storage areas, but always inspect items the next day for contamination. Also confirm that items were placed in the correct storage location, and that you received what was purchased.
Food Rejection
Some items can be reconditioned for use, such as dirty cans that can be cleaned and sanitized. But if that’s not possible, the item must be rejected. Set it aside and let the supplier know exactly why it’s being rejected. Obtain a signed adjustment or credit document before they go. Log the rejected item on the invoice or receiving slip.
Food Recalls
Contaminated items are recalled by the manufacturer, or by FDA or USDA recall notifications. Identify the recalled item, removeit from inventory, store separately from everything, label it “Do Not Use” and “Do Not Discard”, and inform staff not to move it. Follow recall guidelines from the manufacturer on whether to throw it away or return it.
Temperature Issues
These are temperature guidelines to follow when receiving food:
- Fresh meat, poultry, fish, and other packaged foods should be checked with a thermometer inserted into their thickest part.
- Reduced-oxygen packages (ROP) and modified atmosphere packages (MAP), like vacuum-sealed items, should be checked by placing a thermometer probe between two packages. Never puncture them.
- Cold TCS foods should be 41°F or lower when received.
- Live and shucked shellfish, and milk should be 45°F or lower, and cooled to 41°F or lower within four hours.
- Eggs should be 45°F or lower, and hot TCS foods 135°F or higher.
- Frozen foods should be frozen solid. Reject frozen foods with fluid stains or ice crystals.
Packaging
Food and non-food item packaging should be original, intact, and clean, protecting the item from contamination. Reject items with tears, punctures, holes, leaks, stains, dampness, or incorrect or missing labels. Reject cans with severe dents in the seam or deep dents in the body, swollen ends, signs of leakage, or rust. Don’t accept anything that seems tampered with or that’s missing a use-by or expiration date. Note sell-by and best-by dates for freshness.
Documents
Food should be delivered with the proper documents. Shellfish have shellstock ID tags noting where they were harvested and that the supplier was reliable. Fish to be eaten raw or partially cooked have documents noting they’ve been properly frozen. Farm-raised fish documents note they were raised to FDA standards. Keep documents for 90 days from the sale of the fish.
Quality of Food
Bad quality could indicate time-temperature abuse. Reject foods that are moldy, have the wrong texture, raw proteins that are slimy, sticky, dry, or that smell, or foods that don’t meet your quality standards.
Food Storage
Proper storage safely preserves food quality. Foods must be labeled, dated, stored in a way that prevents cross-contamination, and rotated.
Food Labeling
Labeling food is basic safety. Anything taken from its original container must be labeled with its common name or a clear and accurate identifier, and be easily discernible by sight. Foods labeled for resale must have the common name or clear identifier; the quantity; list of ingredients in order of descending weight; artificial colors or flavors; chemical preservatives; name of manufacturer, packer, or distributor; and any allergen ingredient.
Date Notation
TCS foods held over 24 hours must be labeled indicating when the food must be sold, eaten, or thrown out. RTE TCS foods can only be stored for seven days, beginning the day they’re prepared or opened. Then they must be discarded. Some commercial foods come with expiration dates. Combined foods (using various TCS ingredients) must use the earliest use-by date.
Temperature of Storage
Storage temperatures keep pathogens in check, so store cold TCS foods at an internal temperature of 41°F or lower, and hot TCS foods at 135°F or higher. Store frozen foods frozen. Storage must be well ventilated with open shelving, and accurate to plus/minus 3 degrees Fahrenheit with a visible thermometer. Don’t overcrowd storage areas to allow for free airflow. Don’t open cold storage doors unnecessarily, and monitor temperatures often.
Stock Rotation
The first-in, first-out (FIFO) method is a stock rotation practice that ensures items with the earliest use-by or expiration dates are used before items with later dates. Locate use-by or expiration dates, store items with the earliest dates in front of items with later dates, use front items first, and toss out anything past its use-by or expiration date.
Guarding Against Cross-Contamination
Preventing cross-contamination during the flow of food is just as important as preventing time-temperature abuse.
Supply Storage
Supplies should be stored in designated areas and at least six inches from the floor and wall. Single-use items like cups, gloves, etc. should be stored in original packaging.
Container Use
Foods should be stored in food-safe containers that are durable, leakproof, and can be sealed. Never use food-safe containers to store chemicals, and never use chemical containers to store food.
Cleaning
Storage areas should be clean and dry, including walls, floors, and shelves. Attend to leaks and spills immediately, and clean carts, dollies, and trays. Store foods in cleaned and sanitized containers. Store dirty linens away from food and food prep areas in clean, non-absorbent containers.
Order of Storage
Foods must be stored in ways that avoid cross-contamination and should be wrapped or covered. Cooler storage requires certain items per shelf in a specific top to bottom order:
- RTE foods
- Seafood
- Whole cuts of pork and beef
- Ground meat and ground fish
- Ground and whole poultry
Location of Storage
Foods should be stored in cool, dry, and clean locations and never in: locker/dressing rooms, restrooms, trash rooms, mechanical rooms, under stairwells, or under water or sewer lines.
Unsafe Food
Expired, damaged, spoiled, unmarked, or improperly stored foods should be thrown out. If an item must be stored until being returned to the supplier, store it away from other food and equipment, and label it so food handlers won’t use it or move it.