Chapter 5

FOOD PRODUCT FLOW

The flow of food describes what happens to food from the time it enters the workplace until it is
served to the customers.

Objective:

In this chapter the student will able to;

 Discuss the correct ways in purchasing and receiving foods;
 Explain the appropriate method of storing perishable, semi perishable and non- perishable
food;
 Evaluate equipment used to transport food products to food establishment.

Lesson: 1 Overview of Food Product Flow

The alternative paths within a foodservice operation that food and menu items may follow, initiating
with receiving and ending with service to the customer

It refers to a process of receiving, storing, thawing, preparing, cooking, holding, serving, cooling and
reheating that the food goes through in a food service facility.
Each step in the flow of food is a general food safety procedure that should be followed to help
reduce the risk of contamination and mishandling which could consequently lead to foodborne illness
outbreaks.

What to expect:

 Identify the steps in flow of food; and

 Explain the steps in the flow of food like Purchasing, Receiving, Storing, Thawing, and
Preparing.
Purchasing

Effective purchasing paves the way for successful food service operations. Purchasing is a highly
skill-based activity that requires a wide-ranging knowledge of products and market conditions.
Purchasing involves obtaining foods in the right quantity, of the best quality, at the right time, in the
right place, and for the most economical price. A quality-control program in a foodservice
establishment should ensure that only foods which meet written specifications are purchased from
reputable vendors. A good purchaser considers the price, supply, and demand, transportation, and
storage cost before placing an order. Food can easily be contaminated during the various stages of
the food flow, which is why time and correct temperatures need to be monitored closely.

The main objectives of an effective purchasing program are to:

o Buy the product that is best suited for the job;
o Buy the proper quantity;
o Pay the right price, and;
o Deal with only reputable, dependable suppliers.

Purchase specifications are important to both the buyer and the management.
The following are the guidelines that detail the characteristics of a product:
o Quality grade
o Weight
o Count
o Contents
o Packaging
Specifications make the task of comparison shopping easier, since the characteristics of a product
are expressed in a common language and can be used as a basis for evaluation.
Guidelines to Purchasing Food:
1. Understand regulations for specific Foods.
o Purchase packaged or processed foods only from suppliers who receive their products from
licensed, reputable purveyors and manufacturers who adhere to good manufacturing practices.
o Fresh produce may be purchased directly from local growers as there is no inspection process
for these non-potentially hazardous foods (with the exception of melons and fresh alfalfa
sprouts). When making direct purchases, buyers should ensure the packages are clean and
will maintain the integrity of the item, as communicated through product specifications.
o Meat and eggs may be purchased from local producers, but because these foods are
considered potentially hazardous, the products must be inspected for safety. Beef or pork
processed in a state-inspected locker may be purchased by a food service operation. Poultry
must also be processed in a state-inspected locker or facility. These facilities are required to
have HACCP plans in place. State inspection is sufficient if the food is purchased by a food
service within the same state.
o Only pasteurized dairy products should be purchased for service in facilities serving the
elderly. Pasteurized shell or processed eggs should be purchased for menu items not receiving
heat treatment or not reaching 63°C. Pasteurized apple juice and cider can also be purchased
for service to elderly populations.
 2. Visit approved vendors to ensure that they maintain clean warehouses.
3. Observe delivery vehicles to ensure that they are clean and that they practice temperature
control.
4. Use written product specifications to ensure that the vendors know what is to be ordered.
Responsibility of a Manager
1. Develop and implement written product specifications to ensure the products purchased
consistently meet department expectations.
2. Coordinate delivery times with vendors/suppliers to ensure that deliveries are made at times
when they can be stored immediately. Schedule receiving times when product quantity and
quality, including product temperatures, can be checked.
3. Review orders and delivery information to ensure orders and product specifications are met.
Request a written letter from all vendors indicating that they follow either a HACCP program or
good manufacturing practices.
4. Follow up as necessary.

A. Receiving
Strict procedures should be followed when foods are received. All food should be checked for proper
conditions once they are received by the facility. When a delivery is made, it should be checked for
both quality and quantity. Temperature and time are the two most important factors control. The staff
of a food service establishment should check for temperatures and conditions of received foods at
once, so they may be stored as soon as possible.
All refrigerated foods should be put away quickly to prevent time and temperature abuse. Frozen
foods should not have large ice crystals, be discolored or dried out. Canned goods should have
labels, and no swelling, flawed seams, rust, or dents. Never accept home-canned foods to prevent
the risk of botulism.

General Principles when Receiving Food

1. Receive only one delivery at a time from approved suppliers.
2. Check to make sure frozen food is solid and does not show any evidence of thawing and re-
freezing.
3. Record the date received, and if applicable, an expiration date, on the outside of each
package.
4. Remove PHF from the temperature danger zone (50°C to 60°C) and place in storage as
quickly as possible.
5. Check to ensure that refrigerated foods are received below 50°C.
6. Accept only pasteurized dairy products.
7. Reject PHF that are not at acceptable temperature, and cans with swelled tops or bottoms,
leakage, flawed seals, rust, or dents.
8. Evaluate the quality products through their odor, look, and texture. Reject unacceptable ones.
Products must meet specifications and quality requirements. If any foods are deemed
unacceptable, they should be declined and put in a designated area for credit.
Receiving Frozen and Refrigerated Foods
1. Check the products temperature with a calibrated thermometer to assure that cold foods,
especially PHF, are below 5 °C.
 2. Reject, with the exemption of fresh shell eggs (70°C), all foods that are supposed to be stored
below 5°C and are delivered above 5 °C.
3. Check at random and record the temperature of three different types of food items immediately
for each delivery. Record the date, employee initials, vendor, product name, and temperature
of these products in the receiving temperature log.
4. Place foods in the proper storage are (cooler or freezer) quickly to avoid potential bacterial
growth. Proper cool temperatures are 5°C or lower. Proper deep chill storage temperatures are
from -3°C to 0 °C or below. Proper freezer temperatures are -17°C. Proper dry storage
temperatures are between 10°C to 21°C at 50% to 60% humidity.
5. Use the first in first out (FIFO) inventory rotation of products in all storage areas to assure that
the oldest products are used first. Products with the earliest use-by or expiration dates should
be stored in front of products with later dates.
6. Keep products in original packages until use.
Receiving Dry Goods
1. Check dry goods for leaks, flaws, or broken packages. Dry goods should be dry, and free of
mold and insects. If the packages are flawed, they should be rejected and pull in a designated
area for credit.
2. Inspect cans for leaks, incomplete labels, dents, bulges, and other visible signs of damage.
Notify the manager if a damaged can is found.
3. Date boxes and cans with their receiving dates.
4. Separate chemicals from foods.
5. Check delivery invoice against the items delivered and the purchase order.
6. When damaged items are found, the manager or designee should call the distributor so the
product can be picked up and returned and a credit issued. Similar arrangements can also be
made with the delivery personnel. Do not accept the delivery.

7. Note on the invoice any items that were rejected.

B. Storing
All food, chemicals, and supplies should be stored in a manner that ensures quality and maximizes
the safety of the food served to the customers.
Cold holding is storing food at 5°C or below. Refrigeration prevents food from becoming a hazard by
slowing the growth of most microbes. Although some organisms, like Listeria monocytogenes, are
significantly slowed down, their growth cannot be completely stopped by refrigeration.
A walk-in refrigerator is the major storage area in a food service establishment. Its temperature must
be sufficient to adequately hold the food temperature at 5°C or below. A walk-in refrigerator is usually
colder than 5°C to compensate the opening and closing of doors and demands of adding additional
foods for storage and cooling. Foods need to be stored to prevent contamination. All cooked food and
those that will receive no further cooking should be stored above other foods. Foods need to be
stored in a manner that allows space for air to circulate around them.
All canned foods and dry ingredients should be stored in a designated area. Foods should not be
stored in areas such as restrooms, furnace rooms, stairwells, or hallways. They should be kept off the
floor and in closed containers.
Storage areas should be well ventilated and pest free. Dry storage areas can become a food source
for rodents and insects. Keeping containers closed, in sound condition, and off the floor help keep it
pest free. Stock rotation is a good management practice.
Foods and chemicals need to be stored separately. Chemicals should be stored below and away
from foods to prevent chemical contamination.
Storage upon receiving:
1. Place foods in proper storage area (refrigerator or freezer) quickly to avoid bacterial growth.
o 5°C or lower refrigerator temperatures.
o – 3 °C to 0 °C or below deep chill storage temperatures.
o – 17 °C or below freezer temperatures.
o 10°C to 21°C at 50% to 60% humidity dry storage temperatures.
2. Place foods in appropriate storage area immediately upon receipt in the following order:
o Refrigerated foods store foods in designated refrigerators. If food products are stored
together in a refrigerator, they should be placed on shelves in the following order:
• Prepared or ready-to-eat foods
• Fish and seafood items
• Whole cuts of raw beef
• Whole cuts of raw pork
• Ground or processed meat
• Raw poultry
• Frozen foods
• Dry goods
3. Keep all food items on shelves that are at least six inches above the floor to facilitate air
circulation and proper cleaning.
4. Store food away from direct sunlight.
5. Place chemicals and supplies in appropriate storage areas, away from food.
6. Rotate goods when placing them storage by placing the new items behind the old ones to
ensure that the older items are used first (FIFO inventory rotation).
7. Make sure all goods are dated with their receiving and expiration dates.
8. Store foods in their original container if the container is clean, dry and intact. If necessary,
repackage food in clean, well-labeled, airtight containers. This can also be done after a
package has been opened. Food should never be put in chemical containers and chemicals
should never be placed in food storage containers.
9. Store PHF no longer than seven days at 50°C from date of preparation.
10. Store pesticides and chemicals away from food handling and storage area. They must be
stored in their original, labeled containers.
Storeroom Sanitation:
1. Maintain clean and uncluttered storage area. Storage areas should be positioned to prevent
contamination from areas where garbage is stored.
2. Dispose items that are beyond their expiration dates.
3. Store all items on shelves that are at least six inches above the floor to facilitate air circulation
and proper cleaning.
4. Check for signs of rodents and insects. If there are signs of their presence, notify the food
service manager.
Temperature Control
1. Check the temperature of all refrigerators, freezers and dry storerooms at the beginning of
each shift. This includes both internal and external thermometers when appropriate.
• Refrigerator temperatures should be between 2 °C and 5 °C.
 • Freezer temperatures should be between -23 °C and -17°C.
• Storeroom (dry storage) temperatures should be between 10°C and 21°C.
2. Record temperatures, as well as the employees initials, on the appropriate temperature log.
3. Take corrective actions if temperatures are out of the recommended range.
4. Do not overload refrigerated storage areas as this prevents air flow and makes the unit work
harder to stay cold.
5. Be cautious when cooling hot food in the refrigerator, as this warms the unit and can put other
foods into the temperature danger zone.
6. Keep units closed as much as possible to maintain proper temperatures.
7. Defrost units on a regular schedule to aid in proper maintenance and air circulation.
Responsibilities of a Food Service Manager:
1. Check logs and temperatures of storage rooms, freezers, and refrigerators.
2. Review logs to make sure there are no temperatures deviations.
3. Document all corrective actions taken on the appropriate forms.
4. File logs with HACCP records.
C. Thawing
All foods should be thawed using the appropriate practices to ensure food safety.Thawing
foods may take several hours or days depending on the size of the food item being thawed.This must
be done to reduce the risk of cross-contamination and lessen the time that PHF is in the temperature
danger zone (5°C to 60°C).
Steps for Thawing Food:
1. Use one of the three acceptable methods for thawing food:
o Thaw food in the refrigerator at 5 °C or below. Never thaw food at room temperature.
o Thaw food that is needed for immediate service under potable running water at 21°C or
lower. Prepare the product within hours of thawing.
o Thaw the product in the microwave if it needs to be cooked immediately.
2. Use the lowest shelf in the cooler for thawing raw meat to prevent cross-contamination and
separate raw products from cooked and ready-to-eat products.
3. Do not freeze thawed food, unless they are cooked or processed.

Responsibilities of a Food Service Manager:

1. Review procedures to assure they are done correctly.
2. Take corrective actions as necessary.
3. Follow up as necessary.
D. Preparing
The preparation and service of foods can involve one or more steps. Regardless of how many steps
may be involved in food production and service, foodborne illness prevention requires effective food
safety measures to ensure good personal hygiene and avoid cross-contamination and temperature
abuse.
During preparation, an important technique that can be used to promote safety is small batch
preparation. Food preparation is usually done at room temperature. This is several degrees into the
temperature danger zone. The amount of time in the danger zone should be limited by working with
small, manageable amounts of potentially hazardous ingredients.

Guidelines in Preparing Safe Food:

 1. Start with clean, wholesome foods from reputable suppliers. Whenever applicable, buy
government-inspected meat, dairy and egg products.
2. Handle foods as little as possible. Use tongs, spatulas, or other utensils instead of hands.
3. Use clean, sanitized equipment and work tables. Clean and sanitize cutting surfaces and
equipment after handling raw poultry, meat, fish, or eggs and before working to another food.
4. Clean as you go. Do not wait to clean the work place until the end of the workday.
5. Wash raw fruits and vegetables thoroughly.
6. When bringing foods out of refrigeration, do not bring out more than what can be processed in
an hour.
7. Keep foods covered whenever possible unless in immediate use.
8. Do not mix leftover with freshly prepared foods.
9. Chill all ingredients for protein and potato salads before combining.
Keeping Food out of the Temperature Danger Zone
Anytime the food is in the temperature danger zone, bacterial growth can occur. The danger zone
is between the range 5 °C to 60 °C.
1. Limit the time food is in the temperature danger zone. Remember from receiving to service,
food should not be in the zone for more than four hours total.
2. Use a food thermometer to take temperatures. Most menu items have specific time and
temperature requirements for cooking. Insert the thermometer in different areas of the product,
especially in the thickest part. Remember, the temperature of the equipment (stove, oven,
steam, table, etc.) is not the best temperature to check.
3. Use batch cooking (preparing food in small amounts).
• Thaw only what is needed, and keep the rest refrigerated.
• Work only with an amount that can be prepared in less than four hours. Return the food
to the refrigerator if something else needs to be done.
• Cook the food as close to serving time as possible.

Food Thermometers
Food thermometers should be used frequently to maintain food temperature control. They can
measure internal temperatures ranging from -10°C to 104°C.Food temperatures should be checked
with a thermometer regularly. Foods used in outdoors service or in an excessively warm room will
require more frequent checking. The food service operator may also want to record the temperature
readings in a log. This can be very helpful should food temperature issue arise at a later time.

The following are the most commonly used thermometers:

o Bimetal Instant Read (most common food thermometer)
o Thermocouple
o Bimetal-Oven Safe
o Digital
o Infrared
o Oven Thermometer
Preparing Cold Food:
Temperatures of all cold food should be taken during preparation to ensure the safety of all food
served. Food must be prepared using appropriate practices and procedures to ensure safety and
sanitation.
Employees preparing cold food should:
Take Temperatures:
1. Use a calibrated thermometer to take the temperatures of PHF products.
2. Wipe the thermometer stem with alcohol wipes prior to and after taking the temperatures of
food; or wash, rinse, and sanitize the stem.
3. Record temperatures in the Service Temperature Record.
Prepare Cold
1. Foods:Pre-chill ingredients for food that needs to be served cold (sandwiches and salads)
to below 5 °C before combining them together.
2. Discard thawed PHF that has been above 5°C for more than four hours.
3. Discard cold PHF after four hours if they have not been properly held below 5 °C.
Maintain food contact surfaces:
1. When possible, use color-coded cutting boards for all products red for raw meat, green for
vegetables, or fruits, and yellow for raw poultry.
2. Food contact surfaces should be smooth, can be easily cleaned and sanitized, and made of
the appropriate material.
3. Clean and sanitize all food contact surfaces prior to and after use. Cleaning and sanitizing
steps need to be done separately for effectiveness.
Prepare foods
1. Prepare food at room temperature in two hours or less. The food item should be returned to
the refrigerator in cases where it cannot be used at once. The total time of food at room
temperature should not exceed four hours.
2. Prepare raw products away from other products.
3. Clean and sanitize all surfaces, cutting boards, and utensils that have been used in the
preparation of raw meats, poultry, and fish prior to using them for fruits, vegetables, and ready-
to-eat food.

Lesson 2: COOKING
All foods will be cooked using appropriate practices and procedures to ensure safety. This
includes properly cooking foods with the required internal temperature and taking and recording
temperatures.
Cooking is the thermal heating of foods at sufficient temperature over time to kill microorganisms in
the food. Cooking requirements are based on the biology of pathogens since different species of
microorganisms have different susceptibility to heat.

What to expect:

 Identify the steps in flow of food; and

 Explain the steps in the flow of food like cooking, Holding, Serving, Cooling, Reheating
and transportation of foods ;

To effectively eliminate pathogens, there are a number of factors to consider, such as the of
pathogens in the raw product, the initial temperature of the food, and the bulk of the food. Another
factor to consider, to kill the pathogenic organisms in food, is that cooking must heat all parts of the
food to their required temperatures.
 Food characteristics also contribute to the lethality of cooking temperatures. Heat penetrates
different foods at different rates. While a high fat content reduces the lethality of heat, high humidity in
the cooking container or the moisture content of the food aids the effectiveness of heat.
Employees involved in the production of food must complete the following steps:
Prepare hot foods.
1. Cook hot foods to these minimum end-point temperatures or higher. Avoid overcooking. Use a
calibrated thermometer to check the products temperature in the thickest part of the item.

Cooking Guidelines (FDA, 2000)

Food Type
Poultry
Stuffing, stuffed meat,
casseroles, and other dishes
combining raw and cooked foods
Potentially hazardous foods
cooked in microwaves
Ground or flaked meat
Pork
Beef and pork roasts
Beef steaks, veal, and lamb
Commercially raised game
animals
Fish, and foods containing fish
Shell eggs (for immediate
service) Note: if it is not fully
cooked, use pasteurized eggs.
Vegetables (canned, frozen,
fresh)
Ready-to-eat commercially
processed and packaged foods
Minimum Internal Temperature at
Minimum Time before serving
74 °C for 15 seconds
74°C for 15 seconds
74 C;
let food stand for two minutes after
cooking; stir during the cooking
process
68°C for 15 seconds
63°C for 15 seconds
63°C for 4 minutes
63 °C for 15 seconds
63 °C for 15 seconds
63 °C for 15 seconds
63°C for 15 seconds
57°C for 15 seconds (held above 57
°C)
57 °C for 15 seconds(held above
57°C)

2. Take end-point cooking temperatures.

3. Reduce the holding time of foods before serving by using batch cooling.
4. Allow the cooking equipment to return to their required temperatures between batches.
5. Do not use hot holding equipment to cook or reheat foods.
6. Expose food ingredients to room temperature for two hours or less. Food items should be
returned to refrigerator if not used at once. The total time that food can be at room temperature
shall not exceed four hours.
7. Prepare products that will not be cooked or heated away from other products.

Take temperatures
1. Use a calibrated thermometer to take the temperatures of all PHF products by batch.
2. Wipe the thermometer stem with alcohol wipes prior to and after taking the temperatures of
each food, or wash, rinse, and sanitize the stem. Open the sanitizer package with clean hands.
 3. Take temperatures in the thickest part of a food item (usually the center). Two readings should
be taken in different locations to assure thorough cooking on the appropriate end-point
temperature.
4. Record the end-point cooking temperature on the cooked food temperature log.
Responsibilities of a Food Service Manager:
1. Review logs daily to ensure that temperatures and corrective actions are being met and to take
corrective action as necessary.
2. Follow up as necessary and file logs with HACCP records.
3.
G.HOLDING
Once a food is heated or cooked, the food must be maintained at a holding temperatures to limit the
growth of bacteria. The correct hot holding temperature is 60°C.
Once food has been reheated, the potential for the growth of pathogenic bacteria is greater than the
potential in raw foods. The spoilage organisms that may be present in the raw foods inhibit the growth
of pathogenic organisms by competition. Once a food is cooked, these spoilage organisms are
reduced.
All hot food should be held hot, above 60°C, and cold food should be held cold, below 5 °C.
Temperatures of food must be taken routinely to ensure that proper temperatures are maintained
through holding to ensure the safety of the food served, especially to children. Any conflict between
food quality and food safety must always be decided in favor of food safety. When in doubt about the
safety of food, throw it out.
Employees involved in the production or service of food must:
Hold hot food.
1. Prepare and cook only as much food as is needed i.e., use batch cooking.
2. Use hot-holding equipment that can keep hot food at 60 °C or higher.
3. Follow the manufacturer’s instructions in using hot-holding equipment. (Note: customize
your SOP by including instructions. For example, you may need to indicate that the steam
table wells need to be filled with hot water and at what level.)
4. Keep hot foods covered to retain heat and to keep contaminants from falling into the food.
5. Measure internal food temperatures at least every two hours using a probe thermometer.
Record temperatures in a food temperature log. If temperatures are below 60°C, reheat the
food at 74 °C.
6. Discard hot food after four hours if they have not been properly held at or above 60°C.
7. Do not mix freshly prepared food with food being held for service.
8. Do not add raw food to cooked food.
9. Stir food.
Hold cold food.
1. Use cold-holding equipment that can keep cold foods below 50°C.
2. Measure internal food temperatures at least every two hours using a probe thermometer.
Record temperatures in a food temperature log. If temperatures are above 50°C refrigerate
the food.
3. Protect cold food from contaminants by using covers or food shields.
4. Discard cold PHF after four hours if they have not been properly held below 5°C.
5. Place cold food in pans or on plates, never directly on ice. The only exceptions are whole
fruits and vegetables that need to be washed after holding.
 6. Ice used on a display should be self-draining. Wash and sanitize drip pans after every use.
Responsibilities of a Food Service Manager
1. Review logs daily to ensure that temperatures and corrective actions are being met
2. Follow up as necessary.
3. File temperature logs with HACCP records.

H. SERVING
Once food has been prepared for serving, it will no longer undergo any heat treatment. It is therefore
important not to recontaminate food by practicing proper serving methods that would assure the
consumers of safe, hygienic food.
Employees involved in the service of food must observe the following procedures:
Cleaning and sanitation.
1. Clean the area on and around the service line using warm, soapy water and clean cloths.
Thoroughly rinse it after cleaning.
2. Sanitize the area on and around the service line, using an approved sanitizer.
3. Wipe down the area before service begins, and as needed throughout the service.
4. Cloths used for cleaning food spills should not be used for anything else.
Service Utensils / Service wares:
1. Store utensils properly with the handle extended above the container, or on a clean,
sanitized food-contact surface.
2. Use serving utensils with long handles to keep hands away from the food item.
3. Clean and sanitize utensils before using them. Use separate utensils for each food item.
4. Handle glassware and dishes properly.
5. Hold flatware and utensils by their handles.
Good Personal Hygiene
1. Wash hands before handling place setting or food.
2. Do not touch cooked or ready-to-eat foods with bare hands. Always use gloves or utensils.
3. Wash hands after each task. For example, if an employee will take out clean dished after
loading the dirty ones, a thorough handwashing must be done between the two tasks. Hand
dips are not enough.
Service
1. Take temperatures of foods at the beginning of each service period.
2. Record temperatures on the service temperature record.
3. Take temperatures of foods when changing their pans to assure that proper serving
temperatures are achieved.
Responsibilities of a Food Service Manager:
1. Supervise employees to ensure that proper service techniques are being followed.
2. Review logs daily to ensure temperatures and corrective actions are being met.
3. Follow up as necessary.
4. File logs with HACCP records.
Service Temperatures
Temperatures of all hot and cold foods are taken during service to ensure foods are maintained at
appropriate temperatures and that food is safe to be served.
Employees who will be setting up the service carts and serving food must follow the procedures:
 1. Use a calibrated thermometer to take temperatures of food products at time of service.
2. Wipe clean thermometer stem with a new alcohol wipe prior to taking the temperature of any
food item.
3. Take temperatures of all hot and cold PHF as soon as they are put on the service cart or just
before service. The temperature of milk should also be checked before they are taken to
rooms.
4. Record temperatures on the service temperature log.
5. Check to make sure that all temperatures are within the critical limits:
• Hot foods above 60°C
• Cold foods below 5°C
6. Take corrective action, if needed. If hot foods are below 60°C, they must be reheated to above
74°C before putting on the service cart. If cold foods are 5°C or above, they must be chilled to
below 5°C.
Responsibilities of a Food Service Supervisor
1. Check the logs on a daily basis to ensure that they are completed and that the temperatures
are appropriate.
2. Review the log to see if there were temperature deviations.
3. Check corrective action taken to determine if it was appropriate.
4. Follow up as necessary.
5. File the logs in the HACCP file located in the main office.

I.COOLING
Cooling is a process of removing heat from food quickly enough to prevent microbial growth. One
method is by placing foods in shallow containers no deeper than two inches and leaving them
uncovered until cold, 5°C or below.
When PHF is cooled for an extended period, the food is subject to the growth of variety of pathogenic
microorganisms. Bacteria grow ideally between 21°C – 49°C (the human body temperature falls in
this range.)The longer the time period to be held in this range, the greater risk of microbial growth.
Excessive time for cooling PHF has consistently been identified as one of the leading contributing
factors to foodborne illnesses.
When cooked food will not be served right away (or has leftover and can be saved), it must be
cooled as quickly as possible to prevent microbial growth. Temperatures will be taken during the
cooling process to make sure that time and temperature standards are met to ascertain the safety of
food served to the customers.
There are two acceptable methods of cooling foods, employees involved in the cooling process
of food must observe the following procedures:
One-Stage (Four-Hour) Method
1. Cool hot, cooked food from 57 °C to 5°C within four hours using an appropriate procedure.
2. Take the temperature after four hours to make sure that the appropriate temperature was
reached.
3. Reheat food to above 74°C if it has not cooled to 5°C in four hours.
Two-Stage Method (FDA Food Code)
1. Using an appropriate procedure, cool hot, cooked food from 57°C to 21°C or lower within two
hours, and then cool down to 50°C or lower within an additional four hours, for a total cooling
time of six hours.
 2. Take temperatures at the two and six-hour intervals to make sure that the appropriate
temperatures were reached.
3. Reheat food to above 74°C if food has not cooled to 5°C in four hours.
Note: the reason that the two-stage method allows six-hours to cool is that in the first two hours of
cooling, the food is passed through the most dangerous part of the temperature danger zone were
the growth of microorganism is ideal.

Factors that Affect How Quickly Foods Cool Down

1. Size of food - the thickness of the food or distance to its center plays the biggest part in how
fast a food cools.
2. Density of the food - the denser the food, the slower it will cool. Chili soup will take longer than
chicken noodle soup.
3. Container in which a food is stored - stainless steel transfers heat from food faster than plastic.
Initially, loosely wrap food items. Shallow pans allow the heat from food to disperse faster than
deeper pans.
4. Size of the container.
Food may not move through the temperature danger zone fast enough if it is still hot when placed in
the refrigerator or freezer or kept in bulk. The hot food may also raise the temperature of the
surrounding food items, placing them in the temperature danger zone as well.
There are a few methods that can be used alone or in combination to cool foods more quickly.
Methods for Cooling Foods
1. Reduce the quantity of the food being cooled. Cut large food items into smaller pieces or divide
large containers of food into smaller containers.
2. Use blast chillers or tumble chillers to cool food before placing it into the refrigerated storage.
3. Use ice baths. Divide cooked food into shallow pans or smaller pots, then place them in ice
water and stir food items frequently.
4. Add ice or water as an ingredient. This works for foods that contain water as an ingredient,
such as soup or stew. The recipe can initially be prepared with less water than is required.
Cold water or ice can be added after cooking to cool the product and to provide the remaining
water required in the recipe.
5. Use a steam-jacketed kettle as a cooler. Run cold water through the jacket to cool the food in
the kettle.
6. Stir foods to cool them faster and more evenly. Ice paddles (Plastic paddles filled with water
and frozen) and chill sticks can be used to stir foods through the cooling process. Stirring food
with these cold paddles chills food very quickly.

Responsibilities of a Food Service Manager

1. Review logs daily to ensure temperatures and corrective actions are being met.
2. Follow up as necessary.
3. File temperature logs with HACCP records.
J.REHEATING
Reheating is the thermal process to heat foods that have been previously cooked and cooled in a
food service establishment. Proper reheating can eliminate a major portion of pathogens as long as
the food is heated to 74°C within two hours.
The more a food is processed, the greater the risks are form contamination caused by personnel,
equipment, procedures, and other factors. When food is cooked and cooled, the product goes
through the temperature danger zone several times, thereby increasing the risks for microbial growth.
Employees reheating food should
1. Remove leftover food from the freezer/refrigerator.
2. Check the foods temperature using a calibrated thermometer to make sure it is lower than 5°C.
3. Reheat food in an oven, stove, or steamer so that all its parts reach a temperature reading of
74°C for 15 seconds. The goal is to remove the food from the temperature danger zone (5°C
60°C) as quickly as possible. Record the reheated temperature. Discard food that is still in the
temperature danger zone after two hours.
4. Serve the food immediately, or place the food in a steam table or in a pre-heated hot cart, and
recheck the temperature to make sure it is at or above 60°C.
5. Check the temperature of the food before serving if the food has been held.
6. Discard any PHF held in the temperature danger zone (5°C-60°C) for more than four hours.

Responsibilities of a Food Service Supervisor

1. Check the temperature of randomly selected reheated items to be certain that a 74°C
temperature was achieved and that the product is held at 60°C or higher.
2. Review temperature logs to assure proper reheating temperatures are achieved.
3. Follow up as necessary and document corrective actions.
4. File temperature logs wit HACCP records.
K. Transportation of Foods
The popularity of temporary and mobile facilities, such as street fairs, festivals, catering, food
sampling, and mobile carts, have increased rapidly during the past decade. The public patronizes
these events in increasing numbers. In addition to the opportunity for community involvement,
commercial and non-commercial organizations find it profitable to sell food at temporary facilities.
All foods transported from central kitchen to satellite locations (temporary and mobile food facilities)
should be handled in a matter that ensures the quality and safety of food. Protecting the food and
food preparation equipment from contamination is the function of the structure. A temporary food
stand should have:
o An overhead covering.
o An enclosed area, except for the serving windows and an entry door, and;
o A source of hot and cold potable running water for handwashing, cleaning and sanitizing.
Employees involved in the production and/or transportation of food from a central or regional kitchen
to a satellite location must be responsible for both the safety and sanitation of handled food. Steps
include:
1. Preheating of the holding equipment
2. Using calibrated thermometers to take temperatures of food
3. Calibrating thermometers weekly or immediately if dropped, and;
4. Recording temperature and time in temperature log.

Responsibilities of Employees at Central or Regional Kitchens

1. Take temperature of food when it leaves the central kitchen. Hot foods should be at or above
60°C and cold food should be below 5°C.
2. Record temperatures in the temperature log.
 3. Take temperature of food when it is returned from a satellite location.
4. Discard cold foods that are above 5°C.
5. Discard hot foods that are not above 60°C.
6. Chill hot foods that are above 60°C. The product must be cooled to 21°C in two hours from the
last 60°C reading and to 50°C or below in four additional hours. If that is not possible, dispose
of food.
7. Record temperature in the temperature log.
8. Record the product name, date, temperature, and time.
9. Place chilled food in freezer.
Responsibilities of Employees at Satellite Location:
1. Take temperature of food when it arrives at the satellite location and record.
2. Check temperature of food on serving lines every two hours, or more often if temperatures are
near the temperature danger zone (5°C-60°C).
Responsibilities of a Food Service Manager
1. Review logs daily to ensure the temperatures and corrective actions are met.
2. Follow up as necessary.
3. File temperature logs in HACCP file.

*********************************END OF CHAPTER****************************