Week 4: Topic: The Flow of Food

Objectives:
1. Explain how each steps of the food service process affect food safety.
2. Evaluate equipment used to transport food products to food establishments.
3. Recognized product defects & refuse acceptance of products that not meet established
food safety criteria.
4. Discuss safe methods to thaw frozen foods.
5. Identify internal temperature requirements for cooking foods.
6. Explain the proper methods used to cool foods

Key Terms:
Flow of Food- The path that food follows from delivery to service and consumption.
Approved Supplier- A reputable company in compliance with regulatory authority.
Shelf-life- The time under proper storage conditions that food will remain microbiologically
safe and/or of good quality
Spoilage - Process that occurs that makes food unacceptable to consume; spoilage may be
attributed to spoilage microorganisms

The food flow describes what happens to food from the time it enters the workplace until it is
served to the customer. Food product flow refers to a process of receivin, storing, 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 outbreak.
There are 8 steps of food service process:
1. Purchasing
2. Receiving
3. Storing
4. Preparing
5. Cooking
6. Holding & Serving
7. Cooling
8. Reheating

Purchasing
Effective purchasing paves the way for a susscessful food service operations. Purchasing is a
highly skill-based activity that requires a wide range of knowledge of the product and the
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 food service estabkishments should ensure that only foods
which meet written specificationsare purchased from reputable vendors.
 A good purchaser considers the price, supply, 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;
1. Buy the product that is best suited for the job
2. Buy the proper quantity
3. Pay the right price and;
4. Deal only witht the reputable and dependable suppliers
Purchase specification are important to both buyer and the management. The following are
the guidelines that details the characteristics of a product:
 Quality grade
 Weight
 Count
 Content and
 Packaging
Specification makes the task of comparison shopping easier, since the characteristics of a
product are express in a common language and can be use as a basis for evaluation.

Strategies for determining food quality

Sensory evaluation – a commonly used methods for making routine quality determinations on
foods received at retail food establishments.

Types of Evaluation:
i. Sense of smell
ii. Touch
iii. Sight
iv. Sometimes taste
Flavor – a combination of smell & taste

Guidelines to Purchasing Food

1. Understand regulations for specific Foods.
– Purchase packaged or processed foods only from suppliers who receive their products from
licensed, reputable purveyors and manufacturers who adhere to good manufacturing
practices.
– 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.
- 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.
– 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 0 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
 Develop and implement written product specifications to ensure the products purchased
consistently meet department expectations.
 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.
 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.
 Follow up as necessary.

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.

Hermertic Packaging – a container sealed completely to prevent the entry & loss of gases &
vapors.
Modified Atmosphere Packaging (MAP) – a process whereby foods are placed in containers &
air is removed from the package.
Sous-vide – French term for “without air”
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 (5 0 C to 60 0 C) and place in storage as
quickly as possible.
5. Check to ensure that refrigerated foods are received below 5 0 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 product’s temperature with a calibrated thermometer to assure that cold foods,
especially PHF, are below 5 0 C.
2. Reject, with the exemption of fresh shell eggs (70C), all foods that are supposed to be
stored below 5 0 C and are delivered above 5 0 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 0 C or lower. Proper deep chill storage
temperatures are from -3 0 C to 0 0 C or below. Proper freezer temperatures are -17 0 C.
Proper dry storage temperatures are between 10 0 C to 21 0 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.

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 0 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 0 C or below.
A walk-in refrigerator is usually colder than 5 0 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.

Proper Storage of Food Stock Rotation – A First In, First Out(FIFO) method.

Types of Storage:
Refrigerator – used to hold potentially hazardous & perishable foods for relatively short
period of time.
Freezer – used to hold foods for longer period of time.
Dry Storage – use to store less perishable items & food that are not potentially hazardous
foods.
Storage upon receiving:
1. Place foods in proper storage area (refrigerator or freezer) quickly to avoid bacterial
growth.

 5C or lower – refrigerator temperatures.-

 -3C to 0 C or below – deep chill storage temperatures. 
 -17 C or below – freezer temperatures. 
 10C to 21C at 50% to 60% humidity – dry storage temperatures.

2.Place foods in appropriate storage area immediately upon receipt in the following order:
a)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
b)Frozen foods
c)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 5 0 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 0 C and 5 0 C. 
Freezer temperatures should be between -23 0 C and -17 0 C. 
Storeroom (dry storage) temperatures should be between 10 0 C and 21 0 C.
2. Record temperatures, as well as the employee’s initials, on the appropriate temperature
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.

Preparation and Service

In small food establishments, such as convenience stores, food products are commonly
purchased in ready-to-eat form and are stored until sold to the consumer. Large operations,
such as restaurants, supermarkets, and institutional feeding facilities, prepare and serve food
in vast quantities.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”.

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 0 C to 60 0 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).
a)Thaw only what is needed, and keep the rest refrigerated.
b)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.
c)Cook the food as close to serving time as possible.

Thawing
Thawing frozen foods is a common activity in food establishments. The most common and
acceptable methods for thawing foods include: in a refrigerator, in a microwave oven followed
by immediate cooking, under cool running water, and as part of the cooking process.
Proper thawing methods:
Under refrigeration that maintains the food temperature at 41 o F or below.
Completely submerged under running water
- At a water temperature of 70 o F or below.
- With enough water velocity to remove contaminants from the surface of the food.
- For a period of time that does not allow thawed portions of redy-to-eat foods to rise above
41 o F.
- For a period of time that does not allow thawed portions of a raw animal food requiring
cooking to be in the temperature danger zone for more than a total time of 4 hours .
As part of the cooking process.Use any procedure that thaws a protion of frozen ready-to-eat
food that is prepared for immediate service in response to an individual consumer's order.

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.

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 product’s temperature in the thickest part of the
item.
Food Type Minimum Internal Temperature at
Minimum Time before Serving
Poultry 74C for 15 seconds
Stuffing, stuffed meat, casseroles, and other 74C for 15 seconds
dishes combining raw and cooked foods
Potentially Hazardous food cooked in 74C; let food stand for two minutes after
microwave cooking; stir during the cooking process
Ground or flake meat 68C for 15 seconds
Pork 63 C for 15 seconds
Beef and pork roast 63 C for 4 minutes
Beef steaks, veal, and lamb 63 C for 15 seconds
Commercially raised game animals 63 C for 15 secinds
Fish, and foods containing fish 63 C for 15 seconds
Shell eggs (for immediate service) Note: if it is 63 C for 15 seconds
not fully cooked, use pasteurized eggs.
Vegetables (canned, frozen, fresh) 57 0 C for 15 seconds (held above 57 0 C)
Ready-to-eat commercially processed and 57 0 C for 15 seconds (held above 57 0 C)
packaged foods
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.

Holding and Serving

 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 0 C.Once a food is cooked, these spoilage
organisms are reduced.
 All hot food should be held hot, above 60 0 C, and cold food should be held cold, below
5C.
 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 0 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 0 C, reheat
the food at 74 0 C.
6. Discard hot food after four hours if they have not been properly held at or above 60 0 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 5 0 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 5 0 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 0 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.

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 / Servicewares:
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.

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 0 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 0 C – 49 0 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 0 C within four hours using an appropriate procedure.
2.Take the temperature after four hours to make sure that the appropriate temperature was
reached.
2. 3.Reheat food to above 74 0 C if it has not cooled to 5 0 C in four hours.
 Two-Stage Method (FDA Food Code)
1. Using an appropriate procedure, cool hot, cooked food from 57 0 C to 21 0 C or lower
within two hours, and then cool down to 5 0 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 0 C if food has not cooled to 5 0 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.

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.

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 0 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 0 C.
3. Reheat food in an oven, stove, or steamer so that all its parts reach a temperature reading
of 74 0 C for 15 seconds. The goal is to remove the food from the temperature danger
zone (5 0 C – 60 0 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 0 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 0 C-60 0 C) for more than four
hours.