6 replies to this topic

[foodie linda]

Hi All,
 
I would like to ask your expert opinion about our sandwich preparation process. We have a centralized kitchen which supplies sandwiches to our restaurants everyday. They will prepare the sandwiches 2 times a day (each time between 70 - 100 pieces).

 

The ingredients are bread, butter, salad + tomato (sanitized at commisary kitchen), homemade ham slice (prepared by our butchery kitchen) or tuna chunks (supplier) or smoked duck (supplier) or egg mayo, cheese. All ingredients kept in storage 0°C-4°C before preparation starts.

 

My question is, do we need to prepare the sandwiches in controlled temperature? Currently we're preparing the sandwiches in temperature 19°C - 24°C. I've checked and it takes about 34 minutes to complete 70 pieces of sandwiches. If we're unable to control the temperature, will time be the CCP for preparation step? Preparation includes portioning, spreading of butter, arranging vegetables, cutting (chicken/ham/duck), spreading the fillings, cutting the prepared sandwich, packing and labeling. 

 

After that all, prepared sandwiches are kept inside the chiller (0°C-4°C) waiting to be transferred to restaurants. From the centralized kitchen, all sandwiches are delivered to the restaurant using our delivery truck, temperature is 0°C-4°C. Since there is no killing process after, I assume storage and delivery is a CCP (temperature).

 

Thanks for your help and time.

 

 

  

[Tony-C]

Hi Linda,

 

You will need to validate your process for the maximum preparation time and temperature. Confirming product temperature profiles during this process and demonstrating that the sandwiches meet your microbiological criteria at end of shelf life.

 

Your preparation time seems quite reasonable given that I have seen temperature control regulations stipulating a maximum of 4 hours outside the chill chain.

 

Kind regards,

 

Tony

[nile]

Below is extract from IFSA guidelines for food processing for Airline catering

CP 3: Control of Food Processing

Standard

The facility must have a time/temperature control system for safe handling of Time/

Temperature Control for Safety (TCS), ready-to-eat (RTE) foods.

Purpose

To prevent growth of pathogenic micro-organisms to harmful levels during

handling

Scope

All TCS, RTE foods.

Guidelines

Critical Limit Options

1. Room temperature is < 5 °C/41 °F:

No time or temperature control/record is required (Not a CCP or CP in

this scenario).

2. Room temperature is > 5 °C/41 °F but <15 °C/59 °F:

Food exposure time must not exceed 90 minutes.

3. Room temperature is > 15 °C/59 °F but < 21 °C/70 °F:

Food surface temperature must not exceed 15 °C/59 °F or food exposure

time must not exceed 45 minutes.

4. Room temperature is > 21 °C/70 °F:

Food surface temperature must not exceed 15 °C/59 °F and food exposure

time must not exceed 45 minutes.

Monitoring from

maximum of 5°C /

41°F

Check and record room temperature

And:

If Critical Limit Option 1 – no additional checks.

If Critical Limit Option 2 – check and record food exposure time.

If Critical Limit Option 3 – check surface temperature at the end of process

OR food exposure time at end of process.

If Critical Limit Option 4 – check surface temperature at the end of process

AND food exposure time at end of process.

Corrective Action

If critical limit is exceeded, discard food

[GMO]

What is "typical" in the UK is prepared sandwiches will be made in a room at c. 12oC and then chilled below 4 asap.  While it's perfectly legal to have temperatures higher in the UK at least, the colder it is the lower the risk of Listeria monocytogenes.  You have to assume with produce that your tomato and salad are probably not 100% decontaminated.  It is definitely worth monitoring that and also doing everything you can to reduce risk.  The risk will of course be lower the shorter your shelf life.  It's also worth knowing which restaurants they go to.  A general café in the street is one thing, a restaurant in a hospital, maternity unit or school is a very different thing.

[foodie linda]

You will need to validate your process for the maximum preparation time and temperature. Confirming product temperature profiles during this process and demonstrating that the sandwiches meet your microbiological criteria at end of shelf life.

 

 

Actually didn't thought about this until you pointed it out. Thanks Tony!

[foodie linda]

 

Below is extract from IFSA guidelines for food processing for Airline catering

CP 3: Control of Food Processing

Standard

The facility must have a time/temperature control system for safe handling of Time/

Temperature Control for Safety (TCS), ready-to-eat (RTE) foods.

Purpose

To prevent growth of pathogenic micro-organisms to harmful levels during

handling

Scope

All TCS, RTE foods.

Guidelines

Critical Limit Options

1. Room temperature is < 5 °C/41 °F:

No time or temperature control/record is required (Not a CCP or CP in

this scenario).

2. Room temperature is > 5 °C/41 °F but <15 °C/59 °F:

Food exposure time must not exceed 90 minutes.

3. Room temperature is > 15 °C/59 °F but < 21 °C/70 °F:

Food surface temperature must not exceed 15 °C/59 °F or food exposure

time must not exceed 45 minutes.

4. Room temperature is > 21 °C/70 °F:

Food surface temperature must not exceed 15 °C/59 °F and food exposure

time must not exceed 45 minutes.

Monitoring from

maximum of 5°C /

41°F

Check and record room temperature

And:

If Critical Limit Option 1 – no additional checks.

If Critical Limit Option 2 – check and record food exposure time.

If Critical Limit Option 3 – check surface temperature at the end of process

OR food exposure time at end of process.

If Critical Limit Option 4 – check surface temperature at the end of process

AND food exposure time at end of process.

Corrective Action

If critical limit is exceeded, discard food

 

 Thanks Nile! Really needed this :)

[foodie linda]

What is "typical" in the UK is prepared sandwiches will be made in a room at c. 12oC and then chilled below 4 asap.  While it's perfectly legal to have temperatures higher in the UK at least, the colder it is the lower the risk of Listeria monocytogenes.  You have to assume with produce that your tomato and salad are probably not 100% decontaminated.  It is definitely worth monitoring that and also doing everything you can to reduce risk.  The risk will of course be lower the shorter your shelf life.  It's also worth knowing which restaurants they go to.  A general café in the street is one thing, a restaurant in a hospital, maternity unit or school is a very different thing.

There's actually no standard set in Malaysia for preparation temperature (M'sia has very basic food safety standard for now). And yes, based on our previous microbe test results, our salads are still high in coliform 10² -10³(no pathogens detected). All our sandwiches go to our hotel and casino restaurants and kiosks. Generally, our main consumers are adolescents + senior citizens.  Currently our practice is all sandwiches prepared in room temperature for 30 min - 1 hour (depending on numbers of sandwiches they are preparing). Shelf life set at restaurants/kiosk is 3 hours (if they sell in room temperature - I'm afraid some kiosks do not have cold storage) or 1 day (for sandwiches in chiller 0°C-4°C).

 

Thanks for your input GMO. Will definitely include time/temperature monitoring for preparation :) :)