NUTRITION AND
FOOD SAFETY
VCF3083
FOOD PRODUCTION
FLOW
Dr. Mohd Yusof Bin Kamaruzaman
[Link]@[Link]
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 Hot Holding
• Cooked food needed to • Cooked food as required
be rapidly cooled down and then keep it at
to at least 4OC within 6 constant temperature
hours maximum. 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
