NUTRITION AND

FOOD SAFETY
VCF3083
FOOD PRODUCTION
FLOW
Dr. Mohd Yusof Bin Kamaruzaman
yusof.kamar@ftv.upsi.edu.my
CONTENT
▪Food Flow (Food Production Flow) ▪The steps in Food Flow
▪ What is it? 1. Receiving
▪ Why is it important? 2. Storing
3. Thawing
▪Basic Steps of Food Flow 4. Preparation
▪ Relevant steps
5. Cooking
▪ Common commercial food flows
6. Cooling
▪Initial step before Food Flow 7. Reheating
▪ Purchasing 8. Hot/Cold Holding
9. Serving
 ▪What is it?
▪ The steps that food goes through from receiving (as
ingredients) to the serving step (safe and edible
THE FOOD foods).

FLOW ▪Why is it important to know?

▪ Poor food handling throughout each steps may cause
contamination or bacterial growth.
▪ By understanding the individual steps and their processes, foodborne
illness can be prevented successfully throughout
BASIC STEPS IN FOOD FLOW
 Purchasing
INITIAL STEP  Ensure the food (ingredients) are safe.
 Acquisition from approved and reputable suppliers.

BEFORE
 Practice good food safety system
 Through report.
 Certificates documentations

FOOD FLOW  HALAL

 GMP
 HACCP
1. RECEIVING
 ▪Delivery of ingredients
▪ Done by supplier
▪ 2 critical elements:
▪ Scheduled on suppliers' and receivers' agreement
▪ Receivers' staff’s availability
▪ Prompt receiving and storing - eliminate further

1. RECEIVING spoilage
▪ Suppliers' delivery schedule
▪ Avoiding delivery on peak periods.

▪Receiving and Inspection

▪ Appointed personnel only
▪ Able to make decisions
▪ Quality check
▪ High responsibility
 ▪Inspection aids
▪ Thermometer
▪ Temperature sensitive materials
▪ Refrigerated ingredients (0℃ - 4℃)
▪ Frozen ingredients (-18℃ or below)
▪ Weighing scale
▪ Weight accuracy
▪ Report Documents
▪ Invoice Incident/Return Reports

1. RECEIVING ▪Importance
▪ Initial Safety Inspection
▪ Contamination
▪ Spoilt items
▪ Signs of items' faulty
▪ Fraud riddance
▪ Shortage in items supplied
▪ Wrong specification of received items
▪ Wrong item purchased and received
▪ Theft riddance
▪ Record of amount received and kept in storage.
2. STORING
 ▪Keeping items safe in designated space for
future use.
▪Rational of having stored items
2. STORING ▪ Ingredients stocking
▪ Production planning
▪ Smooth product projection
 2. STORING
Dry Storage Refrigerator/Chilled Freezer/Frozen
Relative
10℃ - 21℃ 0℃ - 4℃ -18℃ and below
Temperature

• Slatted shelves • Slatted shelves • Slatted shelves

*Walk-in chiller *Walk-in freezer
• 6” off floor • 6” off floor (bottom • 6” off floor
Shelves
(bottom shelf) shelf) and wall (bottom shelf) and
and wall (body) (body) wall (body)
• Dry
• Low moisture • Avoid constant door • Avoid constant
inhibit microbe opening door opening
growth • Hot air causes • Hot air causes
Other
• Avoid direct condensation on condensation on
requirements walls walls
sunlight
• UV rays might • Regular • Regular
degrade food temperature check temperature check
quality
2. STORING
▪Storage Arrangement
▪ Items grouping by nature
▪ Food ingredients
▪ Wet
▪ Dry
▪ Chemicals
▪ Labeling
▪ Documentation for date received
▪ Crucial for repackaging of items
▪ Fully covered/lidded
▪ Cross contamination elimination

▪Issuance
▪ FIFO – First in, First out
▪ The item received first is the first to be used
3. THAWING
3. THAWING
▪Softening of frozen items by melting off ice crystals within the subject
▪Ways to thaw:
▪ In chiller - slow thawing process (24 hours)
▪ Under running water - 21℃
▪ Microwave - incorporation of cooking process all together

Thawed items must not be refreezed for future use

4. PREPARATION
 ▪Direct handling of food
▪Common term: Mise-en-place (Everything in
place)
▪ Pre-cooking steps - getting the ingredients ready
prior to cooking
▪ Avoiding mishandling and delayed production timing

▪Points to consider:
4. 1. Starts with hand washing

PREPARATION  ...and in between tasks - Change of handling raw foods to cooked

foods.
2. Avoid cross contamination
▪ “Clean as You Go”
▪ Always have station, equipment, utensils cleaned and sanitized.
▪ Avoid leaving soiled utensils cluttered on workstation.
3. Avoid temperature abuse
▪ “Work in Small Batches”
▪ Smaller batches ensures thorough temperature travel into food core.
5. COOKING
 ▪Heat treatment
▪Purpose
▪ Making foods more palatable
▪ Destroy most harmful microbes
5. COOKING ▪Points to consider
▪ Differing cooking temperature concerns
▪ Heating Medium Vs. Heated Ingredients.
▪ Standard requirement: Cook foods beyond
Temperature Danger Zone
6. COOLING
6. COOLING
The process of dropping
down temperature of
cooked food from hot to
cool.
Temperature range
 >60℃ to 4℃ or below

Time frame
 Within 4 - 6 hours
 ▪Method:
1. Ice bath

6. COOLING
2. Dividing into smaller pieces/batches
3. Blast chiller

▪Cooled foods should be chilled in

refrigerator immediately after cooling down
7. REHEATING
 ▪Can be done to:
▪ Bring chilled cooked foods to its original cooking
temperature thus serving temperature.
▪ “Re-cook” foods that is left in room temperature within
only 2 hours
7. REHEATING ▪ e.g.: Curry Puffs, Savory pastries etc.

▪Common method:
1. Microwave
2. Stove
3. Oven
8. COLD/HOT HOLDING
 Cold Holding
• Cooked food needed to
be rapidly cooled down
to at least 4OC within 6
hours maximum.
Hot Holding
• Cooked food as required
and then keep it at
constant temperature
greater than 60OC.

• Food that served chilled • Depending on nature of

needs to be kept cooled food, temperature to keep

8. COLD/HOT •
within 0OC - 4OC until
served.
Food that served frozen
•
it hot will differ.
Examples:
• Mushroom Cream

HOLDING needed to be held at -

18OC or above.
•
Soup kept at about
75OC (Pizza Hut).
Savory pastries at
• Some frozen foods
needed to be thawed about 64OC
slightly for
consumption. Eg. - Ice
cream is held at -
18OC but served at
about -9OC for ease
of scooping.
8. COLD/HOT HOLDING

Cold Holding Hot Holding

9. SERVING
 ▪Presentation of foods to the consumers for
consumption
▪ Ideal temperature
▪ Arrangements for cosmetic value

9. SERVING ▪Points to consider:

1. Clean personal hygiene
2. Cross-contamination
3. Clean cutlery and crockery
4. Serving steps
END OF TOPIC