Dear Madam A D-tor
1. Product is cooked to a temperature fo 80 to 90 Dg C. Critical limit is 75 Deg c for 2 minute
2. Most of the cases, the temperature reached 90 Deg C
3. Transfer the cooked product immediately to a room maintained at -18 Deg C ( freezer- not a blast freezer)
4. due to the heat heat transfers, freezer room temperature increases to - 5 Deg C to +5 Deg C gradually.
5. when the product temperature reached 65 Deg C ( In 15 to 20 minute), portioning the meal starts...
6. Packing in Al contianer ( for rices) and PE bowls ( for any other side dishes) at 65 Deg C. This prevents condensation...
7. Keep the packed food inside the same room
8. In one hour, the product temperature crosses 30 Deg C.
9. Once it reached +30 Deg C, transfer the food to a food vehicle ( refrigeration unit starts and maintained + 5 Deg C at the time of loading, Once loading finished, switch off the refrigeration of vehicle.
10. 1 hour transportation
11. Distribution ends in 2 hours
12. Consumption of food ends in 4 hours
13. Total life of food after cookign is 10 hours (max)
Random Spoilage reported when the product is packed directly at 70 to 80 Deg C.
It was a tough challenge to rectify the spoilages and replace the process with a non hot non cold food.................But technically I am finding difficulties to proivde the reference standards, except the analysis report of TPC below 10,000 cfu/gm

Most wonder is I recieved special congratulations from their organization to rectify thier long run issues which leads to zero spoilages.............

. .But I need to support their
FSMS now.
As a food safety expert, only option is to recommend the +30 food to blast chilled food and provide micro wave oven at consumer points!!!
REGARDS
Jomy Abraham
Dear Jomy Abraham,
Can you please tell to what temperature the food is heated before packing? To me it also seems strange that after 10 hours at 30 degrees micro is still within the limits. On the other hand, you did not test spore formers or heat resistent pathogens.
If you pack the products at 90 °C, you indeed get condense at the lid of the packing. On the other hand, the air temperature above the product might be > 85 °C and pasteurise the lid. You should validate this, it is only a theory.
I am very curious for your validation plan. Can you inform us, how you validated your process?
You ask for advice in establishing OPRP/CCP limits. By validating you proof that your process settings and limits are capable of producing safe food. So, you should already have these limits. Do you have monitoring plans?