Section 4
Work Instructions

Table of Contents

Introduction

W1Receiving procedures and monitoring

W2Storage

W3Defrosting

W4Preparation

W5Cooking

W6Cooling procedures

W7Reheating procedures

W8Holding

W10Calibration

Introduction

This is an example of a Food Safety Manual that has been developed to assist your learning of HACCP-based food safety programs. The development of food safety programs based on the principles of the hazard analysis critical control point (HACCP) system is the most effective way of ensuring food safety. The manual is intended to be a very general guide for HACCP-based food safety programs that will show you how all the parts of the food safety program come together.

This manual is an example of a HACCP-based food safety program for food service processes that include:

  • cook serve
  • cook chill reheat serve (not extended shelf life cook chill).

We have taken every effort to ensure that the sample guidelines in this manual meet the minimum standard for food safety for the processes described. However, when using these guidelines you need to undertake your own research to be assured that you have met current food safety standards and industry codes for the operations undertaken by the business for which you work.

This section of the manual is made up of the sample Work Instructions (W).The Food Safety Manual provides all the work instructions for food handling processes and procedures. These work instructions provide the practical instructions and critical limits that must be followed when preparing food.

In large scale catering, such as hospitals, nursing homes and childcare centres, food handling processes and procedures must be followed. Any breakdown in good hygienic practices can have very serious consequences.

There are a number of general rules relating to food handling processes and procedures. The Food Safety Manual will set out the rules that conform to food safety legislation and also the critical limits that must be maintained.

Each work instruction in this manual is coded, eg Receiving Procedures and Monitoring is W1, and provides a detailed set of instructions which the business and its staff must follow to ensure that food safety requirements are met.

The work instruction identifies the staff responsible for the activity (eg manager) and also the nature of their responsibilities (eg to ensure these procedures are in place and carried out).

The documentation that relate to the work instruction are also listed. Sample forms included in Sections 5 and 6 are shown in bold.

W1Receiving procedures and monitoring

This work instruction describes the procedure you must follow to take delivery of safe food items. It applies to all deliveries of food.

Procedure
General delivery
  • All goods received must meet food safety and quality standards.
  • All goods delivered must have a delivery docket. Stores personnel will count the goods being delivered and check that the quantity received agrees with the delivery docket.
  • All food items must be fully covered where practical to prevent possible contamination from foreign objects.
  • When receiving food items, the receiver will do a total quality check with the supplier’s deliverer. If needed the manager may be consulted to verify quality aspects.
  • The receiver will visually inspect the goods for colour, texture, general appearance and smell of ingredients, and also for broken and damaged tubs, containers and hygiene or any other signs of damage or deterioration. All labels will be checked to ensure that they are correct and conform to the specifications, product description and use-by dates.
  • Using the Delivery Docket the receiver will tick off each item accepted and mark each rejected item with a cross.
  • Temperatures will be checked and recorded on the Goods in Check Sheet for the following items:
  • frozen food items should be frozen (usually -18C)
  • refrigerated food items should be 5C or below, except raw meat carcasses, which may have a surface temperature of 7C.
  • All products requiring weight checks will be weighed and weights checked from the delivery docket.
  • Incoming goods will arrive at times stipulated on the delivery order sheet, and then be transferred by the receiver, to storage. When possible, food items will be delivered when there is someone from the business present to assess the items.
  • Fresh meat, fish, poultry and smallgoods and ready to eat perishable food item deliveries have preference over all other deliveries. These items will be transferred immediately to refrigerated storage.
  • The business may request that frozen potentially hazardous food may be delivered partially or completely thawed if this is necessary for the purposes of processing. The temperature at delivery must not be above 5C and the food will be placed in a refrigerator (at 5C) immediately after delivery. This food will not be refrozen.
Delivery non-compliance
  • Visual inspection and temperature checks will determine the rejection of goods delivered. The following temperature limits will be grounds for rejection:
  • frozen foods that are not frozen, unless delivered thawed by arrangement
  • refrigerated goods received at temperatures more than 5oC.
  • Any foods above these temperatures should be rejected and returned to the supplier.
  • The following visual inspection details will be grounds for rejection:
  • Tinned and canned foods:

damaged, dented, rusted and/or bulging cans

  • Other goods:

goods that fail the inspection as detailed.

  • Any foods or packaged goods that fail the visual inspection should be rejected and returned to the supplier.
Responsibilities
  • The manager will be responsible for ensuring that staff members who carry out this procedure have the appropriate product knowledge and receiving knowledge. The manager has overall authority, but stores personnel are responsible for carrying out this procedure.
  • It is the responsibility of the manager to ensure these procedures are in place and carried out.
  • It is the responsibility of the receiver and stores staff to ensure that acceptable goods are received and non-conforming goods returned following correct procedures.
Documentation

Forms are located in Section 5 (Monitoring Forms for Supervisors) and Section 6 (Check Sheets for Staff)

Goods in Check Sheet

Delivery Docket

W2Storage

This work instruction outlines the steps you must follow for storing food items in order to minimise the risk of contamination and spoilage.

Procedure
General storage
  • Once received, goods will be transferred to the appropriate storeroom or cool room without delay.
  • All food received will be stored in the appropriate store (dry, chilled, frozen) in their original inner packaging where practical.
  • All outer packaging is to be removed before placing items in the storeroom to prevent possible contamination or infestation by pests.
  • Dry goods bought in bulk (eg flour) may be decanted to purpose specific storage units and labelled with the contents and the use-by date.
  • All food items will be controlled and FIFO (first-in-first-out) used, especially for food items with a limited shelf life and explicit use-by dates. These food items will be stored in a manner that ensures older stock is used first.
  • The manager will ensure that all food items are received, stored and handled in a manner that will prevent temperature variations and contamination.
  • All food items must be clearly identified or labelled with the date of delivery/production, and covered during storage if appropriate with either a lid or plastic film. Container lids must not be stored on the floor.
  • Raw and ready to eat food must be stored separately, ideally in separate cool rooms. If this is not possible, ready to eat food is to be stored on upper shelves above the raw foods.
  • All storage areas will be properly cleaned and maintained at all times.
  • Storage areas will be checked once a week to ensure that stock is rotated, leftovers are date marked, the areas are clean and tidy and that there are no signs of pests. The Dry Storage Check Sheet will be completed to record these details.
Perishable foods
  • Cool room doors are to be kept closed at all times (when not in use), and the temperature of food in cool rooms will be monitored and recorded twice a day. Any deviations in temperatures must be investigated to initiate correction. All refrigeration units will be properly cleaned and maintained at all times.
  • Checks of refrigerators will be made first thing in the morning and in the afternoon and recorded on the Cold Storage Check Sheet. Any food items with an expired use-by date will be discarded.
  • All cooked food items will have the date of cooking displayed.
  • Required storage temperatures are as follows:

Raw meat/poultry/seafood / 0C – 5C
Cooked meat/poultry/seafood / 0C – 5C
Cooked vegetables / 0C – 5C
Dairy produce / 0C – 5C
Dry store / 12C – 18C
Frozen products / Will remain frozen (usually below -18C)
Freezing
  • Foods will only be frozen once. However, if a food defrosts and it can be thoroughly cooked it can then be refrozen. This type of refreezing will be limited to one occasion.
  • For packaged, manufactured frozen foods the manufacturer’s or supplier’s recommendation will be followed for freezing temperature and shelf life procedures.
  • Foods that have been cooked, refrigerated and reheated cannot be frozen.
  • Food handlers will ensure that personal health and hygiene responsibilities are met during freezing procedures.
  • Utensils that have been sanitised will be used when handling food that is to be frozen. Food to be frozen will be placed into sanitised containers.
  • Cooked food will be cooled from 60C to 21C within 2 hours, then to 5C within a further four hours. This will be monitored using a probe thermometer. Shallow containers, placed on racks to allow air circulation, will be used to assist the cooling process. The freezing process will then be monitored to ensure that food is frozen.
  • The Cooling Check Sheet is to be used for recording each batch of food that is to be frozen. The time that the cooling process starts (60C), two hours after starting (21C), and when it finishes (5C) will be recorded on the check sheet.
  • If the food does not reach 21C after two hours of cooling it will be discarded. If the food does not reach 5C after a further four hours of cooling, it will be discarded. Faulty cooling and temperature recording equipment will be reported to the maintenance department to be repaired as soon as possible.
Responsibilities
  • It is the responsibility of the stores and kitchen staff to comply with the procedures.
  • It is the responsibility of the manager to ensure compliance with the procedures. It is the responsibility of the manager to ensure that temperature checks on food are completed.
Documentation

Forms are located in Section 5 (Monitoring Forms for Supervisors) and Section 6 (Check Sheets for Staff)

Cold Storage Check Sheet

Dry Storage Check Sheet

Cooling Check Sheet

W3Defrosting

This work instruction outlines the defrosting procedures that you must follow to ensure the safety of food. It applies to the defrosting of potentially hazardous food.

Procedure
  • Food handlers will ensure that personal health and hygiene responsibilities are met during defrosting procedures.
  • Sanitised utensils and containers will be used when defrosting foods.
  • To defrost foods, one of the following methods will be used:
  • as part of the cooking process, if following the manufacturer’s instructions on the label, eg chips, vegetables etc

or

  • the food will be transferred from the freezer to the refrigerator to allow for sufficient time for the food to be defrosted at 5C or below

or

  • the food will be defrosted using a microwave oven. This is the fastest option

or

  • the food will be defrosted using cold running water. The food packaging must be unbroken and the sink sanitised before and after the process. A separate sink available for this purpose will be used. The process will not allow the defrosting food to be held above 5C for more than four hours. After four hours the food will be used immediately or discarded.
  • Food that is defrosted by any other method will be discarded.
  • One sample of hazardous food or drink, eg meat, fish, chicken, egg, milk, cooked rice or pasta that has been defrosted will be checked and the Defrost Check Sheet completed.
Responsibilities
  • It is the responsibility of all staff to ensure compliance with the procedure.
Documentation

Forms are located in Section 5 (Monitoring Forms for Supervisors) and Section 6 (Check Sheets for Staff)

Defrost Check Sheet

W4Preparation

This work instruction outlines the preparation procedures that you must follow to ensure

the safety of food.

Procedure
  • Food handlers will ensure that personal health and hygiene responsibilities are met during preparation procedures.
  • All utensils that come in contact with food during preparation will have been sanitised. All equipment will be clean, dry and in good working order.
  • Cross-contamination between raw and cooked foods will be avoided.
  • Fruit and vegetables will be thoroughly washed before preparation commences.
  • No eggs with cracked shells or dirt on the shell will be used.
  • Hands will not touch ready to eat food unless the quality of the product requires direct handling.
  • Preparation time for all potentially hazardous foods will be limited to control potential hazards. As soon as possible after preparation, potentially hazardous foods will be refrigerated at 5C or below.
  • The ‘2-hour/4-hour rule’ will be followed for ready to eat potentially hazardous food.
  • One sample of hazardous food or drink, eg meat, fish, chicken, egg, milk, cooked rice or pasta will be checked and the Preparation Check Sheet completed.
Responsibilities
  • It is the responsibility of all staff to ensure compliance with the above procedures.
Documentation

Forms are located in Section 5 (Monitoring Forms for Supervisors) and Section 6 (Check Sheets for Staff)

Preparation Check Sheet

W5Cooking

This work instruction outlines the cooking procedures that you must follow to ensure the

safety of food. It applies to the cooking of all potentially hazardous foods that will not be

eaten immediately after cooking, ie food that is going to be held and then eaten.

Procedure
  • Food handlers will ensure that personal health and hygiene responsibilities are met during cooking procedures.
  • All utensils that are used for cooking will be sanitised prior to use.
  • The following temperatures are the minimum temperatures that will be reached when cooking potentially hazardous foods:

Food Type / Temperature
Beef, pork and lamb mince dishes and poultry dishes / Minimum core temperature of 75C* and held at this temperature for required time
Beef, pork, lamb and chicken and fish dishes that are cooked by wet cooking methods and rice and pasta dishes / Minimum core temperature of 75C* for required time
Whole pieces of beef, pork and lamb that have been boned or rolled, whole stuffed fish / Minimum core temperature of 75C* and held at this temperature for required time
Whole pieces of beef, lamb or pork that have not been boned or have not been rolled / The outside needs to be well cooked providing evidence that the temperature has exceeded 100C. The inside can be rare. However pork should be served medium well for good flavour
Portioned meat cuts including beef, lamb or pork steak, chops, cubes or fillets that are cooked by a dry cooking method / The outside needs to be well cooked providing evidence that the temperature has exceeded 100C. The inside can be rare. However pork should be served medium well for good flavour
Seafood and fish fillets / The product needs to be adequately cooked.

* If cooking a potentially hazardous food and by its nature the food cannot tolerate a high enough temperature to reduce pathogens, the procedures outlined in the section on egg-based products will be followed.

  • The Cooking Check Sheet — Wet Dishes — Meat, Poultry and Fish; Dry Dishes — Poultry and Meat including Boned or Rolled Roasts will be used to record the temperature of each batch of potentially hazardous food that is to be held prior to consumption.
  • The Cooking Check Sheet — Roast Beef, Lamb and Pork will be used to record the appearance of each batch of roast meat that is to be held prior to consumption.
  • When a cooked product has not reached the required temperature, the item will be returned for cooking until it does meet the required temperature.
  • Faulty temperature monitoring equipment will be reported to the maintenance department to be rectified as soon as possible.
Responsibilities
  • It is the responsibility of the chef to ensure compliance with the procedure.

Documentation