HACCP in Your

School
Warehouse Employees
Revised April 2012

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Why Hazard Analysis Critical Control

Point (HACCP)?
To prevent foodborne illness in North Carolina
schools.
Foodborne illness
Caused by eating contaminated foods or beverages

Each year there are:

48 million cases of foodborne illness
128,000 hospitalizations
3,000 deaths
- in 2

Food-as-foe

Mason Jones
Dec. 24, 1999 - Oct. 6, 2005
Brianna Kriefall
3 year old
3

What makes us ill?

Chicken
Meats
Ground meats
Fin fish
Shellfish

(Consumers response, Environics,

2005)

Produce
Poultry
Beef
Eggs
Seafood

(CDC, 2009)

What causes foodborne illness?

Food from unsafe source
Inadequate cooking
Improper holding temperature
Contaminated equipment

Who is at risk?

Infants
Toddlers
Elderly
Pregnant women
Immunocompromised
Taking specific
medications

Poor personal hygiene

5

What food causes illness?

Any food can cause foodborne illness
Even non-time/temperature control for safety foods

Characteristics of a time/temperature control for

safety (TCS) food:
Low acid
Moist
Contains protein

Keep time/temperature control for safety food out

of the temperature danger zone!
6

Temperature danger zone

When food is in the
danger zone, harmful
bacteria can grow,
multiply, and possibly
cause infection
Bacteria can double in
number in as little as 20
minutes

Cross contamination
Bacteria can be transferred from one food to
Eat foods
another if foodReady
is not To
properly
stored
Leftover foods
Store raw food below
cooked or ready-to-eat food
Whole beef, fish, and pork
Properly cover foods
Ground meats and fish
Whole and ground poultry
8

Employee Policies

Employee policies
Uniform policy
Closed/steel toed
boots
Back braces
Gloves

Hair and nails

trimmed

10

Basics of
handwashing
Wet hands with arm water
Apply hand soap
Scrub for at least 10-15 seconds, while cleaning under
fingernails and between fingers
Rinse thoroughly under warm running water
Dry with a single-use paper towel or warm-air hand
dryer
Use paper towel to turn off the water faucet and to open
the bathroom door when returning to work
**Remember that hand sanitizers are not a replacement for
effective and proper hand washing.**
11

When to wash hands

After using the bathroom
After coughing, sneezing,
smoking, eating, drinking
or touching body
Before putting on gloves
After any clean up activity
After handling garbage or
trash

Do not handle food

with bare hands if you
have a sore that
contains pus or that is
infected
Cover affected area
with a bandage, a
finger cot, and then a
single-use glove
12

Reporting diagnosed
foodborne illness

If you have been diagnosed with one of the

following foodborne illnesses, report it to your
manager:

Hepatitis A virus
E. coli O157:H7
Salmonella Typhi
Shigella spp.
Norovirus

13

Exposure to FB illness
Exposure to or suspicion of causing any confirmed
outbreak involving the above illnesses
A member of your household is diagnosed with
any of the above illnesses
A member of your household is attending or
working in a setting that is experiencing a
confirmed outbreak of the above illnesses
**Remember sick workers can contaminate food and
make others sick.**
14

Workbook Example
Employee Health
Policy Agreement
Warehouse - HACCP In
Your School Manual
Page 4
15

Thermometers

16

Thermometers

17

Checking your thermometer

Check the accuracy of
all thermometers:
Daily

For calibration,
prepare in advance
Purchase ice and store
in cooler
Container to hold ice

If not correct, calibrate

18

Calibration
Boiling water method

Ice-point method

19

Cleaning and sanitizing

thermometers
The probe or stem of a
thermometer must be
cleaned and sanitized
before it is used
If only measuring the
temperature of ready-toeat food, the probe or
stem only needs to be
cleaned between uses

20

Facility and
Storage
Preventing cross contamination
Controlling time and temperature

21

Food Labels
Do not remove the labels from commercially
processed food
If removed, label the container with the name of
the contents
Date food items with the month and year
Fresh produce should be dated with month and day

22

Temperature of storage
units

Refrigeration

Must keep food at 41F or colder

Air temperature should be 39F or colder

Freezer
Must keep food at 0F or colder
Air temperature should be 0F or colder
Keep floors dry and clean

Dry storage
Best if temperature is between 50F and 70F
Humidity level should be between 50% and 60%

23

Storage of cleaning chemicals

Improperly stored
chemicals can possibly
contaminate food
Store separate from food,
equipment, utensils,
linen, and single-service
and single-use items

24

Material safety data sheets

Occupational Safety and Health Administration
(OSHA) requires a Material Safety Data Sheet
(MSDS) for all chemicals
On every MSDS, be familiar with the following
sections:

4.0 Fire and explosion data

5.0 Reactivity data
6.0 Spill or leak procedures
7.0 Health hazard data
8.0 First aid
9.0 Protective measures
10.0 Additional information/precautions

25

First In, First Out (FIFO)

FIFO ensures proper
rotation of foods in storage
When foods are received,
put the oldest in the front
and the newest in the back
Past-dated foods will lose
their quality and sometimes
become unsafe
Inventory cycle
26

Salvaged items
Providing a separate and
labeled storage area for
salvaged items
To be taken to Food Bank if
possible

Implementing procedures
for handling and removal of
salvaged, expired, damaged,
or contaminated foods
Disposition of these food
items must also be
documented
27

Are these acceptable?

28

How about this can?

Choose a can that has
these features:
Undented seams

Flat ends which curve

slightly inwards

Straight sides

29

Cross-contamination in
storage
Bacteria can be
transferred from one
food to another if food
is not properly stored
Store raw food below
cooked or ready-to-eat
food
Properly cover foods

30

Proper storage to prevent

contamination

31

Storage layout and cleaning

Cleaning is the process of
removing food and other soils
Maintaining an unobstructed 1218 inch distance from walls to
pallets
Food products stored off floor
by 6 inches or on pallets
Pick up debris and sweep floors
Broken pallets, plastic wrap, etc

32

Application Exercises
Warehouse - HACCP In
Your School Manual
Page 9

33

Equipment
Preventing cross contamination

34

Preventative Maintenance
Preventive maintenance tasks for your facility may
include:

Cleaning condensers of refrigeration and freezer units

Defrosting freezer units
Oiling and lubricating moving parts of equipment.
Changing HVAC filters if applicable
Schedule fire suppression system
Schedule fire extinguisher inspection
Check cords and plugs for equipment operated by electricity
Maintenance of transport vehicles and equipment
35

What preventative maintenance

should be scheduled?

36

What preventative maintenance

should be scheduled?

37

Integrated Pest
Management

38

Pest management
Exclusion
Deny pests access to:
Food
Shelter

Dumpsters and
Recycling Area
Keep area clean
Locate dumpsters away
from doors
Keep lids closed
Use trashcan liners
Empty and clean trash
frequently

39

Pest management
Insecticide application
Leave the job to the
professionals
Avoid contaminating
food
Use baits for ants and
cockroaches

Traps and baits

Use for insects and
rodents
Check rodent traps daily
Leave rodent baiting to
outdoor areas and to the
professionals

40

Pest management
Inspect and date all
deliveries
Discard or return
infested or expired
products
Clean up spills as soon
as possible

FIRST IN

FIRST OUT

41

Label and MSDS

42

Record keeping
Keep track of pest problems and measures taken to
correct those problems

43

Receiving
Purchasing from approved,
reputable suppliers

44

Receiving
Check delivery schedule
Reconcile the amount of product received with the
amount of product ordered
Condition of delivery vehicle
Clean, good repair, proper temperature, no insects, no
rodent droppings, and no meat juices on the floor

45

Receiving
Organize storage space
before deliveries
Inspect food items to
minimize the risk for
foodborne illness and
liability
Insert a food
thermometer between 2
packaged products to
check the temperature
Check dates of perishable
goods
Mark with date arrival or
use by date

Inspecting deliveries for

Tampering,
discoloration, pinholes,
leakage
Unusual packages
Contamination (rodent
activity or insects)
Proper temperatures
(receiving log)

46

Receiving
Unloading food items
Frozen first, refrigerated
second, and dry goods last

Substandard food items

(Rejection policy)
A record should be kept of
rejected food items
Photos should be taken if
necessary

47

Temperature danger zone

When food is in the
temperature danger
zone, harmful bacteria
can grow, multiply, and
possibly cause infection
Bacteria can double in
number in as little as 20
minutes

48

Workbook Tables
Criteria for
Accepting/Rejecting a Food
Delivery
Warehouse - HACCP In
Your School Manual
Page14
49

Criteria for Accepting or

Rejecting a Food Delivery
Food

Criteria for Accept Delivery

Raw meat and

poultry

41F or colder, visible USDA inspection stamp, reddish

pink color or no odor, packaging clean and no tampering

Eggs

Shell eggs at 45F or colder, liquid eggs at 41F or colder,

clean and uncracked, no tampering

Fresh produce

Clean, in good condition and no tampering, if cut or

processed must be 41F or colder

Dry foods

Clean packaging and no tampering and no signs of pest

infestation

Canned foods

Clean container and no tampering, label intact, no rust or

corrosion, no buldges, no sharp dents or on the seam
50

Application Exercises
Warehouse - HACCP In
Your School Manual
Page 15

51

Shipping

52

Pre loading process

Check to make sure
the truck is clean and
remove any debris
Turn on cooler at least
45 minutes
Items to be loaded are
sorted and staged

53

Loading
Wheels are chocked
Dry products first
followed by
refrigerated and then
frozen items
Load to minimize
damage and movement
during transportation

54

Unloading
Travel time with/without
refrigeration (temperature)
Multi-stop delivery process
Kitchen staff available to
receive product
Unload with hand trucks
Store all product in appropriate
location to prevent cross
contamination
55

Catering
Prepared food is handled
to minimize
contamination during
transportation
Vehicles shall be
maintained in a clean,
sanitary condition

Temperature monitoring
Cold foods cold < 41F
Hot foods hot > 135F

Food in transit must be

protected from
contamination and
must meet the
temperature
requirements noted
above
Proper storage at
location
56

Sanitation
Preventing cross contamination

57

Cleaning
Cleaning is the
process of removing
food and other soils
Cleaning agents:

Detergents
Solvent cleaners
Acid cleaners
Abrasive cleaners

58

Sanitizing
Sanitizing is the process of reducing the number of
microorganisms that are on a properly cleaned
surface to a safe level
Sanitizing agents only work on properly cleaned
and rinsed surfaces

59

Locations
Floors, trashcans, utility carts/dollies, storeroom
and shelving
Hand sink, ice machine
Walk in refrigerator and freezer
Transport vehicles

60

How this process works

Washing helps loosen soils and other organic
matter from the surface
Detergent and scrubbing also helps break the
adhesion of microorganisms to the surface

61

How this process works

Rinsing removes loosened soil and detergent
from the surface
This step is important because organic material and
detergent can bind up sanitizer making it less effective

62

How this process works

Applying the sanitizer to clean surfaces actually
provides a kill step for reducing the number of
microorganisms

63

How this process works

The surface is not completely free of
microorganisms, but the number is greatly
reduced

64

Measuring Sanitizer Strength

A test kit that
accurately measures
the concentration of
sanitizing solutions
must be available
The strength of
sanitizing solutions
must be measured
frequently during use
65

Material safety data sheets

Occupational Safety and Health Administration
(OSHA) requires a Material Safety Data Sheet
(MSDS) for all chemicals
On every MSDS, be familiar with the following
sections:

4.0 Fire and explosion data

5.0 Reactivity data
6.0 Spill or leak procedures
7.0 Health hazard data
8.0 First aid
9.0 Protective measures
10.0 Additional information/precautions

66

Workbook Table
Cleaning Schedule and
Procedures
Warehouse - HACCP In
Your School Manual
Page 7
67

How would you clean/sanitize

these items?

68

How would you clean/sanitize

these items?

69

Food Defense

70

Food defense
Protect food from intentional contamination
Disgruntled current or former employee
Members of terrorist or activist groups posing as: cleaning
crew, contractors, truck drivers, visitors, and utility
representatives

Primarily about limiting access to products

Understanding what might happen and monitoring
who has access to food
Identify your vulnerabilities and implement food
defense solutions

Exterior security measures

Providing adequate lighting around the
outside of building
Accounting for all keys to establishment
Locked doors, gates, roof access,
windows
Emergency exits

Loading dock access

Prevent environmental contamination and
infestation by insects or vermin
72

Interior security measures

Accounting for all keys to
establishment
Providing adequate lighting
Emergency lighting and alert
system

Checks/reports suspicious
packages
Bathrooms, closets, etc

Cleaning supplies, pest control

chemicals and other hazardous
material
73

Personnel security measures

Restricting entry to the
establishment
Requiring proof of identity
Escorting visitors

Employee vehicles are identified

and lockers inspected
Training employees on emergency
evacuation procedures
Include a map and meeting location
to account for all employees

74

Incoming Shipments
Restricted access to
loading docks
All deliveries checked
against the roster of
scheduled deliveries
Returned goods are
segregated and records
are maintained

75

Handling a Food Recall

76

Food recall
Occurs when there is reason to believe that a food may
cause consumers to become ill. Can be initiated by a:
Food manufacturer or distributor
Government agency (USDA or FDA)

Causes can be:

Discovery of an organism in a product
Discovery of a potential allergen in a product
Mislabeling or misbranding of food

http://www.fda.gov/safety/recalls/default.htm

77

Snokist canned apple sauce

In May 2011, 9 North Carolina kids reported
vomiting and nausea after eating Snokist apple
sauce.
The canned apple sauce had faulty seals and was
possibly reworked moldy applesauce.
Product oozing out of cans and employees still
served to students.

Snokist recall

79

Food recall issued

Review the food recall notice and specific instructions
Communicate the food recall notice to school cafeterias
Via email, phone, etc

Hold the recalled product

Physically segregate the product (including open containers,
leftovers, etc)

Mark recalled product Do Not Use and Do Not

Discard
Inform the entire staff
80

Food recall
Do not destroy any USDA commodity food without official
written notification from NCDA, USDA FSIS, or
State/Your County health department
Inform Your County PSSs public relations coordinator of
the recalled product
Identify and record whether any of the product was
received in Your County PSS, locate the implicated product
by cafeteria site
Verify that the food item bears the product identification code and
production date listed in the recall notice
81

Food recall
Obtain accurate inventory counts of the recalled product from
every cafeteria site, including the amount in inventory and
amount used
Account for all recalled product by verifying inventory
counts against records of food receiving at the feeding site
Notify feeding site staff of procedures, dates, and directions
to be followed for the collection or destruction of recalled
product
Consolidate the recalled product as quickly as possible, but
no later than 30 days after the recall notification
82

Conform to the recall notice

Report quantity and site where product is located
to manufacturer, distributor, or NCDA for
collection
If USDA commodity must be submitted to NCDA
within 10 days of recall

Obtain necessary documents from NCDA for

USDA commodity foods

83

Conform to the recall notice

Complete and maintain all required documentation
related to the recall including

Recall notice
Records of how food product was returned or destroyed
Reimbursable costs
Public notice and media communications
Correspondence to and from the public health
department and NCDA

84

Power Outage
Preventing cross contamination
Controlling time and temperature

85

Refrigerators
Note the time the outage
occurred
Food should be safe as long
as the power is out no more
than about 4 to 6 hours
Leave the door closed
When open needed cold air
escapes, allowing the foods
inside to reach unsafe
temperatures

86

Freezers
Leave the freezer door closed
With the door closed, food in
most freezers will stay below
41F for up to 3 days
Full freezer should keep food
safe about 2 days
Half-full freezer, about 1 day

You can safely re-freeze

thawed foods that still contain
ice crystals and are 41F or less

87

Thawing
Freezing does not kill microorganisms, but it does slow
their growth
During a power outage, frozen food can begin to thaw,
resulting in the outer surface warming up and allowing
harmful microorganisms to grow
The time it takes for food to thaw depends on:

Amount of food in the freezer

Kind of food
Temperature of the food
Size and insulation of freezer
88

When in doubt, throw it out!

If it appears the power will be off for more
than 6 hours
Ice, dry ice, or frozen gel packs may be used to
keep TCS foods at 41F or below

Moving refrigerated food to a walk-in freezer

or obtaining a refrigerated truck are other
options to keep food safe
Food should not be transferred to
private homes
89

Discarding items
Foods that can safely be stored above 41F for a few
days include:
Whole non-cut fresh fruits and vegetables
Condiments such as ketchup, mustard, relishes, barbecue
sauce, soy sauce, olives
Jams and jellies
Bread, rolls, bagels, cakes (without cream or custard),
cookies and muffins
Most hard cheeses including parmesan, asiago and
pecorino
90

91

Power restored
Identify and discard TCS foods that may have been
above above 41F for 4 hours
Check the internal food temperatures using a food
thermometer and record the temperature.
If practical, separate packages of food in refrigeration
units and freezers to allow for faster recooling.
The refreezing of food may affect the quality and
should be used within a short period of time.

92

Acknowledgments
Food Safety and HACCP Information Prepared
by:
Benjamin Chapman, Ph.D., NCSU, 2012
Audrey Kreske, Ph.D., NCSU, 2012

Pest Control Information Updated by:

Michael Waldvogel, Ph.D., NCSU, 2012

93