A chef
who wants to take the next step in their career needs to understand the
planning, supervision and management requirements of a kitchen.
Organizing the kitchen to operate smoothly requires a thorough understanding of the components of the catering control cycle, as well
as how each part has to be understood, planned and executed. Having this
understanding will help you to ensure consistency and meet allocated budgets.
Supervising work operations is an essential aspect of
ensuring a high-quality, efficient and cost-effective service delivery. In one
way or another, all operations impact on the end product or service delivery to
the customer. Operations should be conducted in such a way that the quality of
your product and customer service is maximized.
Supervising and monitoring the designed processes and
procedures and making this revision part of a continuous improvement process
ensure that organizational or enterprise goals are achieved.
Careful planning of the food production
processes
will allow the chef to use the best options for the various menu items.
•equipment
and space-plan the menu so that the
use of equipment is spread over all of the menu items.
•style
and
types of food – café
to fine dining have different requirements
• Client preferences
and expectations will impact the production processes and timelines as they will
define how simple or complex the tasks are.
•skillsets needed by the staff- kitchen hand to the qualified chef
•Operational
plan- well-run establishment will have a clear
direction and purpose.
•special
needs
and requests- dietary
requirements, families needing a highchair, disability access
•
Whichever process is chosen it must ensure that the
quality, structure and above all nutritional value, is not diminished. Choosing
the right product, storing it appropriately, preparing it correctly with
minimum waste, cooking it correctly to maximize yield and then presenting it in
an appealing manner must be the ultimate aim.
A production flow chart is a step-by-step procedure
that clearly describes each stage in the process of preparing a product, from
receiving commodities until distribution of the final product. They should be simple, detailing
HACCP and CCP at each stage.
The following information should be included in all
production flow charts:
•Details of products
or commodities received, including data for receiving, packaging, biological,
chemical and physical condition, as well as storage details
•Details of all processing and
preparation stages
•Timeframes and
temperatures during all stages of processing
•Design and features
of equipment used during processing and preparation
•Details of re-thermalization and cooling
procedures
•Storage locations,
times and temperatures
•Distribution details
and customer feedback
Once you have established a flowchart for a dish on your
menu, the HACCP team should follow each production step in order to physically
verify them and to suggest corrective actions where required.
1.Selection
of
the raw commodities –GIGO
rule – garbage in,
garbage out, check weights and quality
2.
Storage of raw materials – All deliveries must
be stored within defined timelines and using processes based on food safety
principles, to keep food at the appropriate temperature and humidity levels.
3. Preparation – Food safety
principles must be applied. Cutting boards and utensils must be changed and
cleaned appropriately for the preparation of all food items to prevent
cross-contamination, but is especially important for high risk foods such as
seafood, meat and poultry.
Frozen foods must be
thoroughly thawed before use. Rapid high temperature thawing can lead to the
growth of pathogens and could mean the core of the food may not reach the
required temperature.
4. Cooking – When cooking food
items ensure that the core temperature of the food reaches at least 65°C and is
held at this temperature for at least 2 minutes to destroy any pathogenic
microorganisms. Use a proper food thermometer that is checked regularly
calibrated for accuracy.
5. Portioning – Once the food is
cooked it must be chilled down immediately. Portioning can be
done after chilling.
Containers used for chilling food must be food grade, allow rapid chilling, and
should not be too deep (~7.5cm maximum). All containers that are used must have
been stored under hygienic conditions.
6. Blast Chilling – The blast chiller
must chill the food to below 5°C within 2 to 4 hours of commencing the blast
chill cycle. This ensures safety & food quality. Your blast chiller should
be equipped with a food probe for monitoring the core temperature of the food.
7. Storage of chilled foods – Chilled food
immediately must be stored below 5°C to control the growth of microorganisms. It is
recommended to have separate fridges or coolrooms for cook/chill products to ensure that the temperature
control is constant. Chilled food can be kept
safely for up to five days – ensure correct stock rotation using the FIFO
principle. All food should be identified using color-coded labels carrying
information on the use-by-date, production date, and clear product
description. Any food that has reached a temperature in excess of 5°C must be
destroyed.
8. Distribution – Food being
transferred or transported must remain within the defined temperature
guidelines while it is being moved. Refrigerated vehicles are best, but
insulated containers may be used. Temperature probes and dataloggers should be used to
ensure the correct temperature is maintained throughout transportation. The
food must be placed into correct storage immediately upon arrival. Any food
items that reach the danger zone must be destroyed.
9. Reheating – any reheating or
re-thermalizing must be done within 30 minutes after the food has been removed
from storage. Commercial
microwave ovens are
suitable for individual portions of some items. Food must be reheated above
70°C core temperature and be held at this temperature for at least 2 minutes. A
food thermometer should be used to check the core temperature.
10. Service – Re-heated food should
be consumed within 15 minutes of reheating. The temperature of the food should
not be allowed to fall below 65°C. Cooked and chilled foods that are consumed
cold, such as a terrine, should be served within 30 minutes after removal from
storage.
The key processes for food production used in kitchens
are:
Cook-chill –
short (5 day) shelf life- This
process is used to produce fully cooked food that is then chilled rapidly and
stored under controlled conditions until needed. The meals can be distributed
to where they will be used, e.g. from a commissary kitchen to service outlets.
They will then be re-thermalised and used for service.
The process relies on a piece of equipment know as a
blast chiller. The blast chiller uses a high-powered refrigeration system and a
fan to blow cold air across the item to be cooled. This allows the item to be
cooled quickly, while maintaining food quality.
Using this process the food can last for up to 5 days. All hot food must be
re-thermalised correctly to achieve the required core temperature of at least
70°C. The use of HACCP in the
process is crucial to prevent any contamination, food spoilage and food poisoning. The process of cook-chill
means that menu items can be cooked, chilled, stored and re-thermalised without
losing much nutritional value. This allows the operation to conduct much of the
production well in advance of service.
Cook-chill - long shelf life - strict HACCP processes, food is cooked in specialised
equipment, rapid chilling process and minimal handling
Food Preparation and
Cooking - Food is
prepared at a commissary kitchen strict HACCP
protocols. It is then cooked in
large volume.
Bag Fill - Once the food has reached the correct temp, above 70°C,it
is filled into special cook-chill
bags.
Bag Seal - The bag is securely closed with a clip
or heat seal Rapid
Chilling - The
sealed bag is immediately chilled either in a specially designed tumble chiller
or by submerging the bag into iced water, stopping the cooking process & reducing the core temperature to below
5°C within 1 hour,
stored immediately in
appropriate conditions, then HACCP procedures must be followed during
distribution, reheating and service.
Applications
Canteens, Institutions (Hospitals, Prisons, Aged Care,
Childcare facilities), Functions, Events, À la carte – satellite operations
Advantage- Central kitchen,
reduced need for infrastructure and staff
Reduced time pressure during service
Good presentation
on large scale if regeneration is used
Nutritional value & Consistent quality
Minimal waste
Longer storage timeframes
Disadvantage
Expensive set-up cost of operation
Staff training to for correct use of equipment &
processes
Some limitations for particular cookery methods, e.g.
steaks, some seafood preparations, etc.
Requires refrigerated vehicle for transportation to
outlets
Cook-freeze- similar to a cook-chill long
shelf life process, but the food is cooked and then packed in shallow covered
trays and frozen quickly to reach -20°C within 90 minutes of cooking. The food
can be stored for months and is reheated following the same steps outlined in
the cook-chill long shelf life process.
Advantages of
cook-freeze:
•Improved food safety
over cook-chill process
•Food is less
temperature sensitive
•Easy to handle and
transport
•Longer product
shelf-life
•Requires fewer
deliveries of the finished product to other outlets
•Reduced wastage
•Provides consistent
quality
Cook–freeze
Applications
Canteens, Institutions (Hospitals, Prisons, Aged Care,
Childcare
Advantage - Central kitchen,
reduced need for infrastructure and staff
Disadvantage
Expensive set-up cost of operation
Staff training for the correct use of equipment &
processes
Some limitations for particular cookery methods, e.g.
steaks, some seafood preparations, etc.
Cook fresh - smaller scale- The food items are
prepared fresh from scratch, processed, e.g. par-cooked and then served during
service.
Some convenience products such as stock powder,
seasoning mix, pre-cut vegetables, etc. may be used to address issues such as
lack of space, limitations in staff skills or lack of staff. The shelf life is generally restricted
to 2-3 days. HACCP processes should still be used to maintain food
safety.
The key challenge with smaller scale processing is to
ensure that sufficient food is prepared to allow for smooth service. As client
numbers can be unpredictable and can also depend on external influences, such
as the weather, regular purchasing and preparation between service periods are
common.
Applications - À la carte, Table
d’hôte, set menu, Functions, buffet service
Advantage- canteens and Institutions /
some menu options
Flexibility in terms of special requests as these arise
Optimum use of fresh produce
Best presentation
Disadvantage
Requires more staff
Time pressure during production and service
Depending on cookery methods used for some dishes can be
restrictive in terms of flexibility
Limited to an immediate outlet in terms of
infrastructure other than smaller scale catering
Equipment required to ensure temperatures are maintained
during delivery
Increased food safety
risks where distribution is required
Cook fresh - bulk scale
- Used
in many function
centres, hotels and resorts for functions and banquets. The key challenge
with bulk cooking is that the multiplication of standard recipes does not
always follow a clear linear path. This requires
experience and notes can be made in the standard recipe to assist with bulk
production, e.g. "reduce stock by 20% if cooking more than 50
serves". Bulk cooking requires excellent project management skills to get
all the preparation and cooking processes coordinated. Seasonal changes and
product availability also pose challenges.
Bulk cooking
Applications
Canteens, Institutions (Hospitals, Prisons, Aged Care,
Childcare facilities), Functions, Events, Festivals
Advantage
Central kitchen,
reduced need for infrastructure and staff
Greater range of à la carte dishes offered
Disadvantage
Distribution and equipment required to ensure
temperatures are maintained during delivery
Increased food safety risks where distribution is
required
Quality factors, e.g. nutrition, presentation of items
which require distribution
When selecting a suitable system you must consider the
required equipment, food production processes nutritional requirements and
impacts, workflow and other aspects of the systems. Quite often a combination
of processes is suitable. Cook-chill operations may be suited to banquetting, whilst the
restaurant may most commonly use cook fresh, except for some dishes such as
stews, sauces or braises.
In an already operating business it makes sense to
assess the existing customer base, menus and equipment currently in use. It is
important to evaluate whether the existing systems are functional or have been
decided upon based on preferences or due to equipment restrictions in the past.
The key management approaches for food production are:
•Determining
production requirements for the period
•Using standard
recipes
•Developing workflow
schedules
•Creating specific mise en place lists
Standard Recipe Format- Modern computer-based
systems allow for easy access and adjustment. Databases with search functions
are the most sophisticated approach and allow quick retrieval of recipes by
name or key ingredients. Modern databases can be accessed easily and the recipes
should be broken into sections-
allows staff to find
the recipes . A range of formats is
used, but the key points should focus on the ingredients, method of production
and portion yield. Ideally in commercial kitchens the recipes are calculated
for 10 serves to allow easy multiplication. Multiplying recipes from a base of
2 or 4 serves is also easy.
Workflow and Mise
en Place
-Each production unit
or section will then prepare a daily preparation list for the required mise en place and associated
workflow. The preparation list is used to verify all tasks for the team
members. The workflow will prioritise the various tasks for the team and
individual members.
Starter section- Prawns w pesto wonton &
soy
•Prepare prawns and
peel – tail on, devein, wash and store
•Prepare pesto – wash
herbs, peel garlic blend with oil, nuts, Parmesan and season
•Prepare dipping sauce
– chop chillies, mix with soy and fish sauce and peanut oil, package and chill
•Assemble wontons
ready for service – wrapper, pesto, place prawn on, let tail stick out, wrap up
and seal with diluted cornflour, cover with plastic wrap and chill
•Prepare service
plates
Identifying CCP’S for a meat delivery;-
Only chilled carton meat accepted below 4°C internal
temperature
Has the supplier got HACCP processes in place?
Is received and storage process
in order?
Is the meat preparation process in order?
Is the cooking process measured?
has staff got ownership of the process?
Is documentation in
place?
Once workflows have been established it is important to
monitor and review them,
to determine whether the
workflows you have implemented are in line with achieving organizational goals.
You will need to assess whether they help your staff meet their objectives and
timelines.
It is
important that you ask your staff for feedback on their tasks.
Using a coordinated approach of all production processes
can be useful to determine if any parts of the workflow cause delays or
excessive stress levels
One of the most common causes of operational problems is the excess workload. Even if they get the job
done, the quality of the work may be below standard.
Consider the customer impacts of rushing:
•Inferior products
•Stress, Accidents and injuries
•Long lines at the
counter
•Drinks spilled, Messy plates
•Missed deadlines
As a supervisor, you have the responsibility to solve the
problem.
If a production issue is localized to 1 individual staff
member or production area, then in the short term you might be able to source
other workers from different parties or even kitchens to help with the
workload. You might even need to step in and help!
A good quality end product begins with the basic
ingredients. Inferior commodities will not result in a high-quality end
product, so you must order and receive the correct standard of ingredients. You
must also know how much stock you need, where to store it, how to prepare it
and how the final presentation should look.
Setting standards is a key step for the enterprise. If
you do not have a set standard staff will simply make it up as they go along. The same applies to the
food, as you need to define the type of food that you want to serve, the value
for money provided and the details of the dishes on offer. Once again customers
need to know that the food quality is consistent and in keeping with the overall
philosophy of the establishment.
It is easy enough to produce quality products and
services occasionally, but it is the consistency of quality that is the true the measure of the establishment. If staff perform extremely well one day but are
mediocre the next, then you will not be able to provide good quality, all the
time.
A good
manager will use a quality control cycle, which incorporates all stages of the
catering control cycle. For each stage of the catering control cycle, you will
need to:
•Set standards and
requirements
•Implement observation
and control measures
•Develop reporting,
auditing and feedback mechanisms to identify problems
•Create solutions
based on reports, audits and feedback
An astute manager will consider the following:
•Standard recipes
including preparation time, cooking requirements, food cost, portion size and
desired presentation
•Purchasing
specifications for all raw products defining grade, size, quality and suitable
alternatives
•Correct storage and
stocktake procedures to ensure correct stock rotation and quality control
•Control mechanisms
which comply with HACCP principles, such as logs for temperature control,
receipt of goods and temperatures during cooking, holding and packaging
processes
•Checking mechanisms
during preparation and service in regards to standard and presentation,
including personal hygiene, proper food handling to prevent contamination and
preparation procedures
•Wait staff must use
correct terminology when taking orders so that chefs understand what is
required, e.g. MR means medium rare
•Wait staff to be
organized so that food arrives at the table in optimum condition, e.g. soufflés
and foams must be served immediately before they collapse
•Standards are
required for temperature of food, e.g. hot food must be served on pre-warmed
plates, stored under heat lamps if required and delivered to customers quickly
•All staff must be
trained inappropriate standard operating procedures (SOPs) specific to the
enterprise and must have knowledge of the menu and its components
•A good end product
starts with good quality ingredients. GIGO is
important - garbage in equals garbage out. Explain purchasing specifications in the recipes to reduce ordering issues.
•HACCP program will also
ensure good quality by addressing food safety concerns.
•Applying correct hygiene
procedures to extend shelf life
and will not be in breach
of any critical control points along with the food purchasing and production chain.
You should purchase from reputable suppliers who are accredited and who undergo
auditing of their quality assurance processes.
•Receipt and storage of goods
can be incorporated into the HACCP process. Issues such as delivery
temperature, time taken to store deliveries & storage temperatures are important.
•These processes can be
measured and monitored by using temperature dataloggers, visual observation and reporting at crucial steps.
•A food safety program
(FSP) is essential to
any food business'
quality control procedures. Among other things, it will include guidelines for
ordering supplies, procedures for receipt of goods and requirements for
storage. the whole process must be
documented and staff trained adequately. This is particularly important where
food is produced for high-risk customers such as the elderly, pregnant women
and children.
• All deliveries must
be inspected for quality and should be rejected if they do not meet the
required standard. Frozen
items must be put
into the freezer and
refrigerated items
must be stored in the coolroom under correct conditions
It is important to
incorporate the relevant state legislation and other legal compliance issues
into a well-documented process.
In order to report on stock, you may need
to fill out quality reports. This will help you track the quality of the stock
you have. If there is a problem, e.g. vegetables going limp quickly, then you
can investigate what can be done. It could be that the storage temperature is
incorrect, or that the supplier is delivering inferior quality products.
Quality points you should
check for include:
•Best before/use by dates
•Freshness, e.g.
appearance of fish, limpness of vegetables
•Size and weight, e.g.
liquid components may have leached or evaporated
There are many indicators you can use
to identify whether stock is spoiled or contaminated, e.g.:
•Degradation or
deterioration of flavour, aroma, colour and texture, e.g. limp, discoloured
herbs
•Enzymic browning, e.g. on the
surface of cut apples
•Drying and hardening,
e.g. freezer burnt meat, poorly sealed containers
•Crystallisation of sauces
and other liquids
•Evidence of pest activity
•Surface mould
•Damaged packaging and
exposed surfaces
•Odour
A quality report may be compiled on a
daily basis, periodically or as part of the ordering process.
A well-organized chef will have SRCs and preparation
lists on hand so that all mise en place is carried out
correctly. Being organized at the start of the shift will mean that there are
less pressures during service. Any excessive rushing during service will likely
lead to a reduction in quality, so it is essential to be organized beforehand.
The smoother the operation runs, the higher the quality can be.
Processes
you can implement to
ensure food safety when preparing foods-
•During food
preparation minimize the
amount of time spent in the danger zone.
•Correct handling
procedures- wash, peel and rewash
(WPRW) to prevent physical & chemical
contamination.
•Frequently sterilizing equipment
and using colour-coded chopping boards can assist in preventing
cross-contamination.
•Temperature control
during cooking is important, especially if potentially dangerous techniques
such as sous-vide are used. When pre-cooking food for functions, ensure food is cooked
above 65 degrees.
•The temperature of plated
food must also be strictly controlled. Heat lamps and hotboxes can be used to
keep food out of the danger zone, but using for extended periods of time can
affect the quality of the menu items.
•Portion control is an
important part of quality and consistency
|
Quality
indicators
|
Rack
of lamb
|
Mint
crust
|
Rosemary
jus
|
Sweet
potato puree
|
Seasonal
vegetables
|
|
Appearance
and eye appeal
|
Well
defined eye muscle
|
Crisp
look
|
No
fat, clear
|
Smooth
and well-shaped
|
Good
definition
|
|
Colour
consistency
|
MR
centre
|
Golden
|
Rich
brown
|
Orange
|
Bright
orange and green
|
|
Moisture
content
|
Juicy
|
Not
too dry
|
Rich
viscous
|
Creamy
|
Carrots
rich, beans young
|
|
Mouth
feel and eating properties
|
Tender
|
Crisp
outside and herby
|
Rich
flavour with herb notes
|
Creamy
but not too much dairy
|
Carrots
luscious, beans crisp and fresh
|
|
Plate
presentation
|
Nicely
Frenched
|
Not
too thick
|
Not
too thick
|
Nice
quenelles
|
Well
turned, clean bundles
|
|
Portion
size
|
Correct
|
Correct
|
Correct
|
Correct
|
Correct
|
|
Shape
|
Correct
|
Correct
|
|
Correct
|
Correct
|
|
Taste
|
Correct
|
Correct
|
Correct
|
Correct
|
Correct
|
|
Texture
|
Correct
|
Correct
|
Correct
|
Correct
|
Correct
|
|
Sauces
|
|
|
Correct
|
|
|
|
Decorations
and garnishes
|
Rosemary
sprig – young
|
|
|
|
Chopped
parsley
|
When plating a dish, chefs should
remember that the visual impact of the dish can affect a customer's perception
of quality. The way a dish is presented can impact on customer enjoyment. Many
SRCs include pictures of the final product, so that all chefs know how to
present the dish.
One of the most important quality
control procedures in the kitchen is the inspection of plated dishes at the
pass. Many head chefs stand at the pass during service to organise the workflow and
check each meal as it comes up. Any problems or inconsistencies are addressed
immediately and sub-standard menu items are sent back to the relevant chef or
section.
This final check ensures that the dish
is at the desired standard and that the customer receives what they paid for.
It is better to delay the dish slightly than to serve an inferior product.
Strategies such as staggering booking times can reduce
the amount of rush, which improves the quality of service. Simple systems such
as keeping dockets in the order in which they come in means that all customers
will be served in a reasonable timeframe and no customers are unnecessarily
delayed.
In the kitchen, the dockets are read out and each section concentrates on their
part of the dish,
Once the dish is called away each section finishes their task. The sauce chef mounts the
sauce with butter, pours it over the steak and puts the plate on the pass. The
head chef does a final inspection then the wait staff serves it along with the
other meals for the table.
Quality service requires all dishes for a table to be
served together. Wait staff should have systems in place to remember who
ordered what, such as associating numbers with positions at the table when
taking the order.
Customers with
special diets are just as important as any other customer and expect the same
level of treatment. It pays to have plans
made in advance, e.g. a vegetarian option on the menu. When planning a menu
always consider potential workarounds, such as substituting ingredients.
Remember that these customers have friends and family too, so each service
should be considered a moment of truth.
Communication is very important during service and an organised head
chef will have the kitchen running like a well-oiled machine. The head chef
sets the standard and tone for the rest of the team, so a calm, organised
leader will help to maintain a calm, organised workplace.
ㅍ
Basic factors affecting shelf life of foods to be
packaged which must be considered when packaging food include:
•Currency of shelf
life - for example if a product is made with sour cream and the sour cream is
near the end of the use-by date, then the new product must have a use-by-date
not exceeding that of the perishable ingredient used
•Interaction with
packaging - will the food react with the packaging, e.g. foil and an acidic
food item? This may potentially affect the shelf life
•Temperature -
perishable products may have a maximum shelf life or use-by-date under storage
at temperatures below 5°C. If an item is opened and later returned to
refrigeration by a customer, this may affect the overall shelf life of the food
item. This is a reason why many perishables bear a set of instructions for
storage and use
•Packaged processed food must
be in sealed sterile packaging with appropriate labelling, such as use-by date
and nutritional information
•Keep storage
containers sealed and prevent any physical contamination prior to adding food
•Vacuum packaging
extends the lifespan of food products, however, if food items were affected
prior to the packaging they will still deteriorate, so you need to check for
quality indicators
In some cases, food needs to be transported or
distributed to other areas.
When this
happens, temperature control is of critical importance.
Foods to
be distributed either chilled or hot must be transported in vessels which are
capable of maintaining temperatures outside the danger zone.
Chilled food
must be transported at temperatures below 5°C and hot food must be transported
at temperatures above 60°C.
Frozen food can be transported in special containers
that use liquid nitrogen to maintain the low temperatures until reheating
occurs.
This process
not only ensures consistency of quality, it also helps retain much more
vitamins than other methods.
Factors to consider
when transporting food include:
•Ensure delivery vehicle refrigeration
units are regularly serviced
•Use data loggers to track storage
conditions of food items while in transit
•Organise deliveries
to minimise the amount of travel necessary
•Use efficient storage
and outer packaging to prevent damage to packaging during transport
•Check portable food
storage equipment regularly for efficiency and include equipment in maintenance schedules
To support
quality outcomes, monitoring must occur at all stages of the catering cycle. Random checks such as
assessing whether the delivery has been put away within the allocated
timeframe was at the correct temperature or aligned to the delivery docket,
are used to ensure quality and send strong signals to staff.
One of the key elements of quality control procedures is
responsibility. If staff does not know who is ultimately responsible for each
step then you may as well not bother! This is where job roles or SOPs are
crucial. If it is clearly stated that the sous chef is responsible for the food
orders and the section staff is responsible for deliveries within their
section and the head chef will do a final tasting of dishes before each service,
it makes it clear and no confusion arises.
One of the simplest control mechanisms is to taste the
food during production. Surprisingly, many chefs cook food without tasting it.
The correct use of seasoning is crucial. Season food at the beginning of the
cooking process so that the inherent flavors are developed and come to the
fore. As cooking continues, food can be tasted to ensure that the correct
flavors are developing and seasoning can be adjusted accordingly. If you do
not taste the food, how do you know it is at the desired standard?
Part of the business' food safety program involves
identifying Critical Control Points (CCPs) of the packaging process. Monitoring
involves careful measuring and observation of values at CCPs to ensure that
critical limits are followed.
In order to determine the measures for monitoring
processes, it is vital to establish a method that is most suitable for each
CCP. Monitoring procedures might include periodic measuring, sampling, weighing
and/or reading temperatures. Regardless of which monitoring method is chosen,
the selected method must allow many abnormalities to be identified promptly and
reliably.
In industry, monitoring procedures largely depend on the
volume and application of production processes. Whilst a restaurant or hotel
may use manual control processes and monitoring procedures, it is common for
food processing plants to have automated monitoring processes established
within the production line.
These may include computerized programs at CCPs which
measure levels of sanitizers, flow and consistency characteristics and compare
them to pre-programmed allowable levels, or magnetic fields to safeguard
against contamination by metal objects and temperature sensors.
These systems are often linked to audio and/or visual
warning systems that inform the operators of any breaches. For some breaches,
the system will automatically shut down the production processes. Automated
systems are also capable of highly detailed recording of values to assist with
reporting requirements.
If a monitoring procedure indicates that a critical the limit has been reached, then it is important to implement corrective actions
Corrective actions should be decided upon in advance, so that staff
can implement them as quickly and effectively as possible. Corrective actions could
include, but are not limited to:
•Keeping part of the
batch for testing and analysis
•Removing and
discarding the item or product, or placing it on hold until testing has been
carried out
•Assessing and
rectifying the cause of the hazard
•Seeking professional
advice
If subsequent analysis, e.g. laboratory testing, deems
the product batch as safe, then you might:
•Release the product
from hold
•Document corrective
actions and reviewed procedures
If the test results deem the product unsafe, then you
must destroy it.
As part
of the food safety program, it is important to consider the management
requirements for monitoring and correcting. Management must ensure that all
food handling staff are adequately trained and aware of the consequences of
their actions. The staff must also be supervised by an appropriately qualified
person, who is able to ensure that the policies and procedures of the HACCP
plan are implemented correctly.
All procedures need to be communicated to all
involved in production
processes. Extensive signage and instructions will help staff. Each food premises
requires a food safety supervisor with the authority to take corrective actions
at any given time during the production and service procedures.
Giving quality monitoring responsibilities to staff
means that any shortfalls can be addressed early and potential problems can be
minimized. Communication is an important factor in quality assurance.
Explaining the desired standard, verifying that staff understand the
requirements and communicating during production to make sure the standards are
achieved hinges on a clear communication process.
Any new member of your staff should be able to easily
determine what is required of them. Using the SMART principle
(goals are Specific; Measurable; Achievable; Relevant and Timed) will help you to
define requirements. Writing goals into job descriptions will also help staff
to maintain focus and be useful when conducting performance reviews. Your SOPs
should also be created with the desired level of service in mind. The induction
programs and training are essential in order to maintain a consistent level of
service across all staff and all production and service areas.
It is imperative that you monitor the amount of time
spent by staff on preparation, cooking and service, as staff costs form a large
part of your overheads. Therefore, it is important to purchase the produce of the superior quality or which is partly processed, e.g. portion cut meat, as it
reduces the variance in product and time spent in preparation.
Service standards should also be enforced fairly. If a
staff member goes above and beyond what is expected, then they should be
rewarded for doing so. Likewise, if a staff member is not doing what is
required, then this needs to be dealt with.
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