Instructions for Reduced Oxygen Packaging HACCP

Guidance Template
The purpose of the Reduced Oxygen Packaging Guidance HACCP Templates process is to provide
guidance in developing a HACCP plan.

1. There must be a thorough understanding of HACCP principles when developing a

HACCP plan.
2. The following link can be useful in understanding HACCP:
https://www.fda.gov/food/hazard-analysis-critical-control-point-haccp/haccp-
principles-application-guidelines

ROP HACCP Plan must contain the following:

1. A list of products that will be reduced oxygen packaged.
2. Equipment list/equipment spec sheets.
3. Flowcharts for each product must be included with CCPs identified.
4. Hazard Analysis charts must be completed for each product with CCPs identified.
5. HACCP charts must be completed for each product.
6. The HACCP plan must include process descriptions for each product which
includes but not limited to:
 Ingredients
 Equipment/Materials
 Preparation steps
 Monitoring procedures

7. Standard Operating procedures must be included but not limited to:

 Training program procedures
 Cleaning and sanitizing procedures
 Thermometer calibration procedures
 Designated work area procedures

8. Monitoring Logs must be included such as:

 Product temperature log
 Product date/label log
 Thermometer calibration log

9. Make sure your HACCP plan is complete and customized to the processes in
YOUR establishment or your HACCP plan will not be approved and you will not
be able to conduct reduced oxygen packaging.
 NAME
Street Address
City, State, Zip Code

HACCP PLAN
For Sous Vide
Reduced Oxygen Packaging

General SOPs
Cleaning and Sanitizing
Employee Practices
ROP Procedures
Training Program
HACCP Based SOP’s

[Month Day, Year]

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 SOUS VIDE HACCP PLAN

Products: Cooked meats (beef, pork, goat and lamb) and poultry (chicken)

Ingredients: See attached list

Intended Use: Served in the restaurant to diners or take out

Time/Shelf-Life: 7 Days under cold storage (≤41°F)

PROCESS DESCRIPTION

Sous vide processes are limited to cooking meats and poultry which are vacuum packaged
and intended for in-house restaurant use only for the purposes of cooking products to a
precise temperature for greater consistency, to enhance food flavors and textures, and to
reduce time from order to service. We purchase all of our meats, poultry, and spices from
approved and licensed suppliers and inspect them during receiving for temperature (41ºF
or below) and quality. The handling, preparing, vacuum packaging, cooking, cooling,
storing, and monitoring of sous vided products are conducted by employees who have
thorough understanding of this HACCP plan and are trained in the reduced oxygen
packaging and sous vide processes. The sous vide and ROP operations are conducted only
in the designated areas of the kitchen.

EQUIPMENT LIST

• Circulator: __________________________________________________________________________
• Refrigerators: __________________________________________________________________________
• Slicer: __________________________________________________________________________
• Thermometers: _________________________________________________________________________
• Vacuum Packager: __________________________________________________________________________

HACCP TEAM MEMBERS

NAME TITLE/ROLE

______________________________________ _______________________________________________________________
______________________________________ _______________________________________________________________
______________________________________ _______________________________________________________________
______________________________________ _______________________________________________________________

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 FLOW DIAGRAM

Receiving Raw Meats Receiving of Dry

& Poultry Ingredients & Packaging
(1) Materials (2)

Preparation #1,
Cold Storage (3) Vacuum Packing (6) Dry Storage (4)

Thawing Cooking (7)

(Optional) (5) CCP #1

Cooling (8)
Labeling (9)
CCP #2

Cold Storage (10)

CCP #3

Serving (12) Reheating (11)

________________________________________ _________________________________________ ____________________

Verified by (Name) Signature Date

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 HAZARD ANALYSIS

PROCESS STEP

Process Step Potential Hazards Hazard Justification of Decision Preventative Measures Is this
(B) Biological, (C) Chemical, Significa step a
(P) Physical nt? CCP?

Receiving Raw (B) Salmonella, E. coli, Yes Fresh meat and poultry are Meat and poultry will be purchased No
Meats & Poultry Campylobacter jejune, known to contain pathogens from approved suppliers and
(1) Clostridium Botulinum, etc. received at proper temps.

Receiving Dry (C) Deleterious Chemicals No Letters of guarantee ensuring bags No

Ingredients & Bags (P) Foreign Material. ingredients are from approved
(2) sources and appropriate for
product use

Cold Storage of (B) Salmonella, E. coli, Yes Potential growth of pathogens All meat and poultry will be No
Raw Meats & Campylobacter jejune, immediately stored in coolers and
Poultry (3) Clostridium Botulinum, etc. freezers at 41ºF or below.

Storage of Dry (P) Foreign Material. No Visual inspection of packaging No

Goods & Bags (4) materials to ensure no foreign
material is present.

Thawing (B) Salmonella, E. coli, No Potential growth of pathogens Thawing in refrigerator or under
(Optional) (5) Campylobacter jejune, cold running water insures that No
Clostridium Botulinum, etc. temperature abuse will not occur

Preparation #1 & (B) Salmonella, and E. coli, No Potential growth of pathogens Time product will be in the
Vacuum Packing Campylobacter jejune, due to cross-contaminations is temperature danger zone during
No
(6) Clostridium Botulinum, etc. likely preparation will be minimized and
monitored.

Cooking (7) B) Salmonella, E. coli, Yes Survival of bacterial spores if Products will be cooked to as
Campylobacter jejune, products are not properly required in Plano’s Food Code. Yes
Clostridium Botulinum, cooked to correct internal CCP 1
Listeria, etc. temperatures.

Cooling (8) B) Clostridium Perfringes, Yes Improperly cooling can lead to Products will be cooled to 41ºF as
Clostridium Botulinum and growth of spore-forming Yes
described in Plano’s Food Code. CCP 2
Listeria pathogens

Labeling (9) B) Clostridium Perfringes, Yes Improperly labeled products will Each bag will be properly labeled
Clostridium Botulinum and result in outdated or unsafe with product name, date packaged, No
Listeria products and ‘Use-By’ date

Cold Storage (10) B) Clostridium Perfringes, Yes Potential growth of pathogens if ROP packaged and labeled
Yes
Clostridium Botulinum and proper temperatures and time products will be monitored for
CCP 3
Listeria are not maintained. time and temperature control.

Reheating (11) B) Clostridium Perfringes, Yes Survival of bacterial spores if ROP packaging will be opened prior
Clostridium Botulinum and products are not properly to reheating and product properly No
Listeria heated for hot holding or service.

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 cooked or reheated to correct
internal temperatures.

Serving (12) B) Clostridium Perfringes, Yes Survival of bacterial spores if Products will be served
Clostridium Botulinum and products are not properly immediately after reheating
No
Listeria cooked or reheated to correct
internal temperatures.

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 HACCP FORM
CCP

(1) Monitoring (10)

(2) (9)
Critical (3) (8) Record-
Hazard Verification
Control Critical Limits (4) (5) (6) (7) Corrective Action keeping
Description Activities
Point What How Frequency Who Procedures

Cooking Pathogens Temperatures: Product Use of One food Designated Continue cooking Manager Cooking Log
(CCP 1) Beef: 145°F for 15 temperature thermometer product per food and adjust directly
seconds batch worker circulator temps if observed Thermometer
Pork: 155°F for 15 below designated Monitor daily Validation Log
seconds temp for product
Poultry: 165°F for Cooking Log
15 seconds reviewed daily
by chef.

Cooling Pathogens Temperatures: Product Use of Every hour Designated Reheat to cooking Manager Cooling Log
(CCP 2) 140°F to 70°F in temperature thermometer food temp and restart directly
2hrs or less; 70°F to worker cooling process if observed Thermometer
41°F in additional not cooled to 70°F Monitor daily Validation Log
4hrs or less. in first 2hrs.
Cooling Log
Discard product if reviewed daily
product not cooled by chef.
to 41°F within 4hrs
of reaching 70°F.

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Cold Pathogens Temperatures: Cooler and Use of 2x Daily Designated Immediately Manager Refrigerator/
Storage 41°F or less product thermometer plus food discard product if directly Freezer Log;
(CCP 3) temperature worker temp exceeds 41°F. observed
Identify and Monitor daily
eliminate cause of Thermometer
deviation. Refrigerator/ Validation Log
Time Limit: Freezer Log
Designated
7 days or less Date on ROP Visual check Daily Identify out of date reviewed daily Product Date
food
bag label of the labels worker
products and by chef. and Label Log
on the bag discard them.

Product Date/
Label Log will
be reviewed
daily by chef.

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 SOUS VIDE PROCEDURES
Only foodservice employees trained in the use of the reduced oxygen packaging equipment
and have a thorough understanding of the HACCP plan shall conduct ROP operations.

1. Receiving Raw Meat/Poultry: Inspect meat and poultry products upon receiving for
temperature and quality and verify product temps are at or below 41ºF.

2. Receiving Packaging Materials: Inspect the condition of dry goods and packaging
materials upon receipt. Verify products are in good condition.

3. Cold Storage: Immediately store all perishable products in the designated coolers with
temperatures at or below 41°F.

4. Dry Storage: Store non-perishable products in clean location that is separated from
any potential sources of contamination.

5. Thawing (Optional): Thawing meat and/or poultry in refrigerator or completely

submerged under running water at a water temperature of 70 degrees Fahrenheit or
below with sufficient water velocity to agitate and float off loose particles in an overflow
and for a period of time that does not allow thawed portions of ready-to-eat food to rise
above 41 degrees Fahrenheit, or for a period of time that does not allow thawed portions
of a raw animal food requiring cooking as to be above 41 degrees Fahrenheit, for more
than 4 hours.

6. Preparation & Vacuum Packaging: Prepare products, ingredients, and packaging

materials necessary to the operation according to recipe/instruction. Prepare products
for vacuum packaging and ensure products remain at room temperature no longer
than 30 minutes during the preparation and packaging process.

Place product in the packaging materials. Place bags in the vacuum machine ensuring
that adequate space is provided around each package. Ensure that machine is working
properly and settings are appropriate for the product being packaged. Start the
machine and wait for the lid to open indicating that the process is complete. Remove
packages from the machine. Visually check the seal to ensure that it is tight and that
there are no food materials in the seal. Packages with a faulty seal should be re-
packaged. Trim excess packaging as required.

7. Cooking (CCP #1): Set the circulator bath water to proper temperatures based on the
product being cooked and place the vacuum packaged product in the circulator bath.
• Critical Limit: Follow recipe directions to cook beef flaps to 145°F for a minimum of
15 seconds, pork to a minimum of 155°F for 15 seconds, and poultry products to a
minimum of 165°F for 15 seconds.
• Monitoring: Check temperature of the product and record the cooking temps for
each product on the Cooking Log.

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 • Corrective Action: If temperature is not at the required temperature, continue
cooking. If the temperatures of the circulator bath falls below the appropriate
temperatures, adjust circulator temp and continue monitor cooking temperatures.
• Verification: Chef must verify that designated employees are monitoring and
checking cooking temperatures daily by visually monitoring employees during
their shift and reviewing Cooking Logs on daily basis.

8. Cooling (CCP #2): Remove the bags from the circulator and place them in an ice bath
on the prep table in the ROP station.
• Critical Limit: Cool the products to 70°F within 2 hours of reaching 140°F and to
41°F within 2 hours of reaching 70°F.
• Monitoring: Check temperature of largest of product per batch and frequency to
monitor requirements and record the temps on the Cooling Log.
• Corrective Action: If product is not cooled to 70°F within the first 2 hours, reheat
product to required cooking temperature and restart cooling process or discard. If
product is not cooled to 41°F within 4 hours of reaching 70°F, discard product.
• Verification: Chef must verify that designated employees are monitoring and
checking cooling temperatures daily by visually monitoring employees during their
shift and reviewing Cooling Logs on daily basis.

9. Labeling: Properly label each package with name of product, date packaged and use-
by date. Ensure to use the premade labels that have the statement “Keep refrigerated
or frozen”, and ensure the use-by date is within 7 days of packaging.

10. Cold Storage (CCP #3): Place ROP packages in coolers immediately after labeling.
• Critical Limit: Products must be at or below 41°F and held in ROP packages for no
more than 7 days.
• Monitoring: The designated employees must visually check and record
temperatures of coolers containing ROP products at least twice a day during
business operating times and record temperatures on the Refrigeration/Freezer
Log.
The designated employees must also visually check labels of ROP products for use-
by dates and record the check and any corrective action on Product Date/Label Log.
• Corrective Action: If ambient cooler temperatures exceed 41°F, check actual
product temperatures and if above 41°F, discard the product and notify the
Manager on Duty that the cooler is not properly working. Record corrective actions
on the Refrigerator/Freezer Log.
If the Use-By dates are past the designated date, discard the product and record
corrective actions on the Product Date and Label Log.

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 • Verification: Manager on Duty must verify that designated employees are
monitoring and checking ROP product temperatures and use-by dates daily by
visually monitoring employees during their shift and reviewing Refrigeration/
Freezer logs and Product Date/Label Logs on daily basis.

11. Reheating: Remove vacuum packaged products from coolers and reheat product to
proper temperature (165°F if hot holding; desired temperature for immediate service).

12. Serving: Portion reheated product for meal size and serve as ordered by patrons.

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 SANITATION STANDARD OPERATING PROCEDURES (SSOPs)

EMPLOYEE HYGIENE AND PRACTICES

1. Hands are to be thoroughly washed in a designated hand sink with soap and water,
paying particular attention to the areas underneath the fingernails and between the
fingers by scrubbing thoroughly with using a fingernail brush. Dry with single use
towels. Handwashing is to be done at the following times:
• after using the toilet, in the toilet room
• after coughing, sneezing, using a tissue, using tobacco, eating, or drinking
• after handling soiled equipment or utensils
• immediately before engaging in food preparation activities
• during food preparation as necessary to remove soil and prevent cross
contamination
• when switching between raw and ready-to-eat foods
• other times as needed to maintain good sanitation
2. Fingernails must be kept trimmed, filed, free of nail polish, and maintained so the edges
are cleanable and not rough.
3. Eating and drinking is prohibited in areas where contamination of exposed food, clean
equipment, utensils, unwrapped single service and single use articles could occur. A
food employee may drink from a closed beverage container in a food prep area as long
as it is handled to prevent contamination.
4. Effective hair restraints must be worn in processing areas.
5. Smoking and other uses of tobacco are prohibited.
6. Clean outer clothing must be worn each day and changed as often as necessary
throughout the day (when moving from a raw food operation to a ready-to-eat food
operation).
7. Frocks and aprons used by employees are to be hung in a designated area when not in
use. They are not to be worn in the toilet area, eating areas and locker rooms.
8. Foot wear is to be kept clean.
9. No jewelry (except a wedding band or other plain ring) is allowed during handling of
food.
10. Food Employees shall report to the Person in Charge when they have a symptom caused
by illness, infection, or other source that is:
• associated with diarrhea, vomiting or other acute gastrointestinal illness
• jaundice

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 • A boil, infected wound or other lesion containing pus that is open or draining unless:
if on the hands or wrists, unless a finger cot or other impermeable cover protects
the lesion and a single use glove is worn if on exposed portions of the arms, the
lesion is protected by an impermeable cover.
The Person in Charge shall impose the proper restrictions and exclusions according to rule.

CLEANING AND SANITIZING

Equipment Food Contact Surfaces
Properly cleaned and sanitized food contact surfaces are critical to ensuring a safe, sanitary
operation. Use of approved cleaners and sanitizers will reduce levels of pathogenic
organisms to prevent cross contamination of the product. Detergent cleaners suspend and
help remove various food soils. Chemical sanitizers (chlorine, quaternary ammonia, etc.)
reduce the numbers of pathogens and other microorganism to insignificant levels.

The cleanup process must be completed in accordance with following procedures:

• Pre-cleaning: Equipment and utensils shall be pre-flushed, presoaked, or scraped as
necessary to eliminate excessive food debris
• Washing: Equipment and utensils shall be effectively washed to remove or completely
loosen soils using manual or mechanical means. Only approved chemicals are to be
used in this process.
• Rinsing: Washed utensils and equipment shall be rinsed to remove abrasives and to
remove or dilute cleaning chemicals with water
• Sanitizing: After being washed and rinsed, equipment and utensils must be sanitized
with an approved chemical by immersion, manual swabbing, brushing, or pressure
spraying methods. Exposure time is important to ensure effectiveness of the chemical.
Ensure that an appropriate chemical test kit is available and routinely used to ensure that
accurate concentrations of the sanitizing solutions are being used.

Frequency of Cleaning Equipment, Food Contact Surfaces and Utensils:

1. Before each use with a different type of raw animal food, including beef, fish, lamb,
pork, or poultry;
2. Each time there is a change from working with raw foods to working with ready to eat
foods;
3. Between uses with raw fruits or vegetables and with potentially hazardous foods;
4. At any time during the operation when contamination may have occurred.
5. If used with potentially hazardous foods, throughout the day at least once every four
hours

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6. Utensils and equipment that are used to prepare food in a refrigerated room that
maintains the utensils, equipment, and food under preparation at 41°F or less and are
cleaned at least once every 24 hours
7. Before using or storing a food thermometer.
8. For equipment used for storage of packaged or un-packaged food, including coolers,
and the equipment is cleaned at a frequency necessary to eliminate soil residue.
9. For ice bins, at a frequency necessary to preclude accumulation of soil or mold.
10. Food contact surfaces of cooking equipment shall be cleaned at least once every 24 hrs.

11. Non-food-contact surfaces of equipment shall be cleaned at a frequency necessary to

prevent accumulation of soil residues.

HACCP TRAINING FOR EMPLOYEES

Understanding the potential hazards associated with reduced oxygen packaging.

While the process of packaging foods using a reduced oxygen method extends the shelf life,
it also can pose a serious public health threat. Generally, bacteria survive under conditions
where there is oxygen present (aerobic conditions) or where oxygen is not present
(anaerobic conditions). Some bacteria have the ability to adapt to either condition.

Under traditional packaging conditions (aerobic conditions), spoilage bacteria would

normally thrive and the product would spoil before the more hazardous types of bacteria
might become a problem. During the process of ‘vacuum packaging’ or ‘reduced oxygen
packaging’, the air inside the package (which is approximately 21% oxygen) is eliminated,
creating anaerobic conditions and thereby changing the types of bacteria that can survive
in the package. Spoilage organisms are eliminated, but several types of pathogenic bacteria
survive and actually thrive under these conditions.

The pathogen of greatest concern is Clostridium botulinum. While botulism bacteria will
normally be killed in a cooking step, spores of the bacteria may survive and could grow and
produce toxin if the conditions are right. These conditions are similar to those that occur in
a vacuum/reduced oxygen package. Other pathogens of concern may be Listeria
monocytogenes, Yersinia enterocolitica, Campylobacter jejuni, and Clostridium
perfringens.

CONCEPTS REQUIRED FOR A SAFE OPERATION

A thorough understanding of this HACCP plan, the use of the reduced oxygen packaging
equipment, and the HACCP based standard operating procedures is necessary for the safe
operation of the restaurant’s vacuum packaged products. Areas to focus on include:

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products that can be packaged, temperature control, prevention of cross contamination,
and health and personal hygiene of food handlers.

Products that can be packaged by ROP

HACCP plan defines the foods that can be packaged using reduced oxygen packaging. Only
the specific products on this list can be reduced oxygen packaged. Any addition to the
above list must first have the approval of the City of Plano Environmental Health &
Suitability Division. Changes must be noted in the HACCP PLAN.

Temperature Control

Temperature control is a very important factor in keeping all potentially hazardous foods
safe. But the extended shelf life and decreased oxygen concentration allows certain
pathogens to multiply in reduced oxygen conditions. To reduce the potential for growth of
these pathogens, products (packaged and unpackaged) must be stored at cooler
temperatures of 41oF or less. Employees must monitor the cooler temperatures at least
every 4 hours to ensure that foods are not allowed to be out of the temperature
requirements for extended periods of time.

Preventing Cross Contamination

Raw foods should be handled separately from cooked and ready to eat foods to avoid cross
contamination. Utensils, equipment and work surfaces used for raw foods should be
thoroughly cleaned and sanitized prior to using for cooked or ready-to-eat foods. In
addition, ensure that ready-to-eat foods are stored so that blood or juices from raw
products cannot drip or otherwise come into contact with them. Food handlers can also be
a source of cross contamination through improper handwashing, or soiled clothing or
aprons.

Employee Health and Hygiene

The health and personal hygiene of food handlers can also play a critical role in producing a
safe ROP food. It is vital that employees working in this operation follow the Employee
Hygiene and Practices guidelines.

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 Refrigeration / Freezer Log
Instructions: The designated foodservice employee must record the location or description of holding unit, date, time, air
temperature, corrective action, and initials on this Log on daily bases. Chef or manager must verify that foodservice workers have
taken the required temperatures by visually monitoring food workers during their shift, and must review, initial, and date this log
daily. This log should be maintained for a minimum of 6 months.
Location/ Unit Date Time Temp Corrective Action Initials Verified
Description By

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 Product Date/Label Log
Instructions: The designated foodservice employee must check the date and label of vacuum packaged products and ensure they do
not exceed the use-by date. The employee must record daily date and time the product label is checked, any corrective action, and
initial on this Log. Chef or manager must verify that foodservice workers have checked ROP product dates and labels by visually
monitoring food workers during their shift, and must review, initial and date this log daily. This log should be maintained on file for a
minimum of 6 months.
Location/ Unit Past Use- Verified
Date Time Corrective Action Initials
Description By Date? By

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 Thermometer Validation Log
Instructions: The designated foodservice employee(s) must record the validation temperature and corrective action taken each time a
thermometer is validated. Accuracy of thermometers will be validated using slurry ice water. The Chef or manager must verify that
foodservice employees are using and validating thermometers properly by making visual observations of employee activities during all
hours of operation. The supervisor must review and initial the log daily. This log should be maintained for a minimum of 6 months.
Date Time Thermometer Method Used Thermometer Accurate Corrective Action Initials Verified
ID# (Ice Slurry) Reading (Yes/No) By

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 Cooking and Reheating Temperature Log
Instructions: Record product name, time, the temperatures/times taken, and any corrective action taken on this form. The
supervisor of the food operation will verify that food workers have taken the required cooking temperatures by visually monitoring
food workers and preparation procedures during the shift and reviewing, initialing, and dating this log daily. This log should be
maintained for a minimum of 6 months.
Date Time Food Item Internal Internal Corrective Action Taken Initials Verified
Temp/Tim Temp/Tim By

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 Cooling Temperature Log
Instructions: Record temperatures every hour during the cooling cycle. Record corrective actions, if applicable. The Chef or manager
of the food operation will verify that the designated food worker is cooling food properly by visually monitoring the food worker during
the shift and reviewing, initialing, and dating the log daily. This log must be maintained for a minimum of 6 months.

Date Food Item Tim/ Tim/ Tim/ Corrective Actions Taken Initials Verified
Temp Temp Temp By

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