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Research Article
_______________________________________________________________________
Journal of Tourism, Hospitality
Hazard Analysis and Critical Control Point & Culinary Arts (JTHCA)
2020, Vol. 12 (1) pp 456-473
© The Author(s) 2020
(CCP) determination in cook-chilled Beef Reprints and permission:
UiTM Press
Curry and Beef Kurma Submit date: 31st July 2019
Accept date: 16th August 2019
Publish date: 29th February 2020

Dora Liyana Abd Lataf*1

Nor Ainy Mahyudin2
Ismail Fitry Mohammad Rashedi1
Rasiyuddin Hariri3
Ahmad Zaki Abdullah3
1
Faculty of Food Science and Technology,
Universiti Putra Malaysia, UPM Serdang, Selangor, Malaysia
2
Halal Products Research Institute,
Universiti Putra Malaysia, UPM Serdang, Selangor, Malaysia
3
Felda D’Saji Sdn. Bhd. Malaysia, Kuala Lumpur, Malaysia
*[email protected]

Proposed citation:
Lataf, D. L. A., Mahyudin, N. A., Rashedi, I. F. M., & Hariri, R., Abdullah, A. Z. (2020). Hazard Analysis and
Critical Control Point (CCP) determination in cook-chilled Beef Curry and Beef Kurma. Journal of Tourism,
Hospitality & Culinary Arts, 12(1), 456-473.

Abstract
The first principle of HACCP, the hazard analysis, was conducted to identify the potential hazards
associated with food production at all stages, assess the likelihood of occurrence and severity of the
hazards and to identify control measures. The determination of critical control point (CCP) is when control
can be applied and is essential to prevent, eliminate or reduce the identified food safety hazard to an
acceptable level. In this study, the hazard analysis and CCP determination for cook-chilled beef curry and
beef kurma in a centralised kitchen were carried out. By using the process steps decision tree in
MS1480:2007 standard, two processes were determined as CCPs, which were the boiling process and
rapid chilling process.

Keywords:
Hazard Analysis, CCP, HACCP, Beef Curry, Beef Kurma, School Kitchen

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1 Introduction
The hazard analysis critical control point (HACCP) system is a recognized food safety
approach that addresses potential biological, chemical and physical hazards through preventive
approach, rather than the traditional, cost and time-consuming end product testing. The seven
principles of HACCP were developed as a preventive system for the production of food with high
degree of safety precautions to cater for different types of consumers (Roberts et al., 2014)
The Malaysia Food Hygiene Regulations 2009 stated that the implementation of food safety
assurance program such as Good Manufacturing Practice (GMP) and HACCP is currently regulated
to only food premises involved in the manufacturing of food, mainly the commercial food service
establishments. Although this does not apply to non-commercial food establishments such as
boarding schools, the implementation of such systematic and preventive approach is to ensure
that the food produced are safe for students’ consumption since boarding school kitchens mass-
produced foods approximately for 600 to 1000 students per day at five meals daily.
The purpose of this study was to examine the production of cook-chilled beef cooked in spice
dishes prepared in a boarding school kitchen that also served as a centralised kitchen using the
HACCP principles. Hazard analysis is to identify and analyse the hazards associated with cook-
chilled food production at all stages, from receiving of raw materials to delivery of food to
satellite kitchens, assessing the likelihood of occurrence and severity of the hazards and thus
determining its CCPs in order to ensure food is safely prepared along the production process.
Primarily, this study focused on beef dishes, which are beef curry and beef kurma. The hazard
analysis were conducted using process approach, where two products which uses the same or
similar ingredients and process flow were grouped together under the same hazard analysis
(USDA, 2005).

2 Literature Review
Curry is a widely known spicy food originated from Indian subcontinent that is produced
from curry paste that has a variety of flavourful spices in it. Its red-orange colour is contributed
from the chilli and turmeric powder in the curry paste, which is also made from cumin, coriander,
fenugreek and curry leaves. Kurma or korma is a Mughal cuisine which has a milder flavour
compared to the curry. It is made from a mixture of chilli, cumin, coriander, and fenugreek spices.
It has a pale brown to white colour due to the absence of turmeric powder in it. Meats such as
chicken, fish or beef with addition of vegetables are usually cooked with curry and kurma to make
it a complete dish. In Malaysia, beef curry and beef kurma are prepared in household kitchens,
schools, and restaurants, and eaten with rice or bread.
The safety of food, with regard to microbiological contamination, is a very important aspect
of food preparation, especially when it involves young children. Food safety needs to be
monitored to avoid any occurrence of food poisoning. Many outbreaks of food poisoning and
foodborne diseases have occurred in the past due to the consumption of microbiologically
contaminated food (Holtby et al., 2008; Meftahuddin, 2002; Richards et al., 1993). These are the
results of unacceptable practices during the preparation, storage or delivery of food. Besides,
many basic food handling practices are not implemented in school foodservice. Studies have
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shown violations in time-temperature procedures and handwashing practices in school kitchens

(Dora-Liyana, Mahyudin, Ismail-Fitry, Ahmad-Zaki, & Rasiyuddin, 2018; Henroid & Sneed, 2004;
Youn & Sneed, 2003). Improvements in food safety procedures are indicated by implementing a
food safety assurance program to school food operation.
HACCP, as described in many literatures, is defined as “a management system in which food
safety is addressed through the analysis and control of biological, chemical, and physical hazards
from raw material production, procurement and handling, to manufacturing, distribution and
consumption of the finished product” (Barbut, 2015; Lohalaksandech, Wittaya, & Sujarit, 2012;
Sekheta, Sahtout, Sekheta, Sharabi, & Airoud, 2010; Youn & Sneed, 2003). However, HACCP does
not only depend on management commitment but also prerequisite programs such as good
manufacturing practice (GMP) and other relevant food safety system that provide as the basis
for the HACCP system. Prerequisite programs would include conditions such as personal hygiene,
supplier control, process control, pest control, cleaning and sanitation procedures, traceability
and recall procedures and documented employee training.
HACCP systems are developed through the application of seven principles which are Principle
1 (conduct a hazard analysis), Principle 2 (determine the critical control points), Principle 3
(establish critical limits), Principle 4 (establish a system to monitor control of the critical control
points), Principle 5 (establish the corrective action to be taken when monitoring indicates that a
particular critical control point is not under control), Principle 6 (establish procedures for
verification to confirm that the HACCP system is working effectively) and Principle 7 (establish
documentation concerning all procedures and records appropriate to these principles and their
application) (Roberts et al., 2014; Trafiałek, Lehrke, Lücke, Kołozyn-Krajewska, & Janssen, 2015).
A centralised kitchen is the centre of commissary food service system. Ali and Akbar (2015)
discussed that centralised school lunch preparation provides prospects to food safety through
standards implementation and training of food handlers despite the possibility of a disease
outbreak. The risk of foodborne illness is due to the time gap in food preparation and service of
meal to the school children (Marzano & Balzaretti, 2011, 2013; Richards et al., 1993). Hence,
stringent operating procedures are important to maintain food safety in school foodservice. It
was found that centralised systems implemented more food safety procedures and practices
than did conventional systems (Kim & Shanklin, 1999; Youn & Sneed, 2003). In addition to
efficiencies obtained through centralised production, proponents of these systems suggest that
quality and standardization of food production improves with centralisation. Not only is food
quality improved but a consistent quality nutritional profile in the prepared foods may also be
achieved (Ali & Akbar, 2015; Brown, 2005; Tessi et al., 2002).
Enhancing food shelf life is one way to cater mass food production and this includes food
preparation using cook-chill or cook-freeze method (Man, 2008). The fact that thousands of
meals are served daily requires the foods to be well prepared in advance of service. Cook-chill is
considered a high risk process as it involves precise temperature and time for chilling of food for
a period of time (Elansari & Bekhit, 2014; Eves & Dervisi, 2005).
The hazard analysis using process approach are usually used by foodservice establishments
to enhance food safety and more timely responses to problems (Thapa, Singh, & Karki, 2010;
USDA, 2005). Since foods from the centralised kitchen will be transported to satellite kitchens,

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cook-chill system approach was chosen. Advantages of the enhanced cook-chill system are that
foods can be prepared on a 3-week menu cycle and food preparation; cooking and tray assembly
are independent of mealtime. Enhanced cook-chill technology allows centralisation of food
production and distribution from one source to off-site locations. The centralised production
enables equipment and staff to be utilized continuously instead of just during peak hours
(Langlois, Bastin, Akers, & O’Leary, 1997).
Rapid chilling was used in central kitchens that use cook-chill operation to rapidly decrease
the cooked food temperature to prevent food pathogens growth which can lead to food borne
diseases (Poumeyrol, Morelli, Rosset, & Noel, 2014). Food is cooked to temperature above 63oC
and cooled down in a blast chiller immediately after cooking. This is to prevent bacterial spores
germination that survived during cooking, which can multiply when the environment became
suitable for growth (Poumeyrol et al., 2014; Rodriguez et al., 2011). Hence, the time and
temperature of food at the rapid chilling and cold storage process need to be monitored to
ensure food safety. All chilled foods are vulnerable to temperature abuse during distribution,
display, and storage. It is therefore, essential that temperature abuse be minimised. The
temperature of cook-chill food should be maintained at ≤3°C throughout storage in a cold room
and transported to the satellite kitchens before reheated for serving (Amezquita, Kan-King-Yu, &
Le Marc, 2011; FSAI, 2014; Man, 2008).
3 Methodology
Field observation with the manager and cook of the centralised kitchen were carried out to
get the basic information on the cooking process of beef curry and beef kurma. The selection of
beef curry and beef kurma are because the main ingredient in these two dishes (beef) were
regarded as high risk in terms of microbiological growth (Buncic et al., 2014; Ercolini, Russo, Nasi,
Ferranti, & Villani, 2009). Besides, these dishes were served in boarding schools with the
frequency of twice a month.
The hazard analysis and CCP determination for cook-chilled beef curry and beef kurma
production were based on a comprehensive review of both Malaysian and international
authoritative reports, standard requirements and data of journal articles and scholarly books.
The MS1480:2007 - Food safety according to HACCP system standard (DSM 2007) was
referred for the decision tree for determination of sensitive raw materials and decision tree for
determination of CCP.
The scope of HACCP for this study is from the receiving of raw materials to the delivering of
finished product to satellite kitchens. The satellite kitchens are other boarding school kitchens
located within 200km from the central kitchen. The assessment of the significance of food safety
hazards uses the matrix of the severity and the likelihood as shown in (Mortimore & Wallace,
2013; Schmidt & Newslow, 2013; Wallace, Holyoak, Powell, & Dykes, 2014). There are five groups
of severity caused by hazards which are (i) fatality occurrence, (ii) serious illness, (iii) product
recall, (iv) customer complaint and (v) not significant. The likelihood of hazards is also categorised
into five groups which are (i) common repeating, (ii) known to occur, (iii) could occur, (iv) not
expected to occur and (v) practically impossible. A value of 1-10 indicates a significant food safety

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issue, which means that control measures must be put in place. Non-significant issues will have
values of 11-25.

Table 1: Significance of food safety hazard matrix

Likelihood
Severity A B C D E
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25
Hazard severity: Hazard likelihood:
1. Fatality occurrence A. Common repeating
2. Serious illness B. Known to occur or ‘it has happened’
3. Product recall C. Could occur or “I’ve heard of it
4. Customer complaint happening”
5. Not significant D. Not expected to occur
E. Practically impossible

4 Findings
4.1 Process flow
HACCP process approach were applied in this hazard analysis and CCP determination
because the cooking process and ingredients of the selected dishes were the same except for the
spices used, where one uses curry powder, while the other uses kurma spice powder. Standard
recipes for both dishes were obtained from the chef. These processes of preparing chilled beef
cooked in spices dishes were observed via on-site verification at the selected boarding school
and information about the production processes were collected.
Illustrates the comprehensive process flow chart for chilled beef cooked in spices dishes. The
process of flow starts with the receiving of all raw materials and packaging, and ends with delivery
of finished products to satellite kitchens.

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Figure 1: Process flowchart for cook-chilled beef curry and beef kurma

Four spices (star

Kurma/ UHT anise, clove,
Treated Palm oil (cooking Salt and
curry coconut cardamom, Onion, ginger, garlic Beef Stainless steel tray Cling wrap
water oil), ghee sugar
powder milk connamon stick),
tamarind peel

Receiving

Filter Dry storage Storage (freezer) <-18o C Water Equipment storage

Unpack/ unboxing Water Peeling Waste Thawing <1-4o C for Washing

18-24 hours
Washing Washing Water Washing and trimming Waste Drying

Draining Waste Draining Draining Waste

CCP 1
Slicing Boiling Core temp: >70o C
Time: >10 minutes

Storage (chiller) <1-4o C Draining Waste

1. Heating

2a. Sautéing

2b. Sautéing

Core temp:; >70o C

3. Simmering

4. Packing

5. Labelling

CCP 2
6. Rapid chilling Temp: 0-3o C
Time: 90-120 minutes

7. Storage food bank

(cold room) Temp: 0-4o C
Shelf life: 4 days (inclusive production day)

8. Loading Temp: 0-4o C

9. Delivery Temp: 0-4o C

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4.2 Hazards related with raw material

Identification of hazards in Principle 1 of HACCP are categorised into two, which are hazards
related to raw materials and hazards related with processes. In this step, all potential hazards
associated with each raw materials and steps were listed. Besides that, hazard analysis was
conducted and any measures to control identified hazards were considered. Although hazard
analysis can be conducted using two approaches, this study uses scientific literature review
rather than laboratory testing of the raw materials or process steps of the product. This is
because the latter is costly and time-consuming.
Possible hazards related with raw materials and packaging were categorised into three
hazards, which are biology, chemical, and physical hazards. Different hazards can be found in raw
materials and packaging. The sensitivity of these items was also determined using the raw
material/packaging material decision tree in MS1480:2007.
From the analysis, there is one raw material identified for each beef dishes that relates to
sensitivity of raw material, which is the frozen beef. It is important to identify this raw material
as being sensitive to prevent spoilage of the product that could compromise the food safety.
Bacteria belonging to Salmonella spp., Escherichia coli O157:H7 and Listeria monocytogenes are
most commonly reported pathogens and raw beef is considered as major source of these
pathogens (Shafini, Son, Mahyudin, Rukayadi, & Tuan Zainazor, 2017; Wheeler, Kalchayanand, &
Bosilevac, 2014). This raw ingredient is considered as sensitive raw material because serious
illnesses related to these pathogens from beef could happen and are caused by ingestion of
undercooked or contaminated cooked beef (Garayoa, Vitas, Díez-Leturia, & García-Jalón, 2011;
Kjeldgaard, Stormly, & Leisner, 2010). Preventive measures or controls applied to prevent this
significant hazard is by ensuring product received frozen at temperature <-18oC and under the
documented pre-requisite program for supplier control, process control and receiving of raw
materials.
Chemical hazards related with frozen beef are veterinary drug residue (antibiotic), heavy
metals (cadmium, lead, arsenic) and nitrite (Barbut, 2015; USDA, 1997) which were introduced
during farming or industrial contamination. However, one of the preventive measures taken to
control these hazards is by purchasing frozen beef from registered suppliers. The frozen beef
received were mechanically cut into cubes. Physical hazards related with frozen beef are intrinsic
(bones fragment) and extrinsic foreign objects (metal fragments from the cutting blades).
Although other raw and packaging materials were not determined as sensitive materials,
preventive and control measures should be taken into consideration to prevent the presence and
occurrence of possible hazards. For example, water can harbour ubiquitous bacteria such as
Enterobacteriaceae, Pseudomonas spp., Staphylococcus aureus, Salmonella spp., Vibrio cholera
and Shigella (Bartram, Cotruvo, Ener, Fricker, & Glasmacher, 2003). The possible chemical
hazards in water are pesticide residues, chlorine and heavy metals. However, these hazards were
excluded because the establishment uses potable water and water filter.
The production of beef kurma and beef curry uses palm oil and ghee as fats. Biological
hazards, which are associated with these fats, includes microbial survival (fungi, Pseudomonas
spp., Staphylococcus aureus) (Seiyaboh, Kigigha, Alagoa, & Izah, 2018). Chemical hazards in palm

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oil and ghee are pesticide residue, veterinary drug residue (antibiotic) and aflatoxin M1 (Nazir,
Abdullah, Ariwahjoedi, & Yussof, 2012; Sekheta et al., 2010), while physical hazards include
impurities in the raw material. Although possible hazards may be present in this raw ingredient,
the hazards were not significant. The preventive measure required is to control the hazards using
supplier control pre-requisite program.
Spices (kurma powder, curry powder, star anise, clove, cardamom, cinnamon stick, ginger,
garlic, and onion) can be the medium for possible microbial growth which are caused by improper
storage condition. Wide range microbial contamination may occur during the pre- and post-
harvest handling, thus the rationality for inclusion as hazard (Banerjee & Sarkar, 2003; Lins, 2018;
Sagoo et al., 2009). A study by Fogele, Granta, Valciņa, & Bērziņš (2018) found that moulds from
the species Aspergillus spp. and Penicillium spp. dominates spices such as cumin, curry, cinnamon
and clove. Besides moulds, the same study also found a high concentration of Bacillus cereus
toxin in spices, as spore forming Bacillus cereus are resistant to drying or high heat treatment.
Chemical hazards such as the addition of food additives and level of pesticide residue and
heavy metal above the permitted limit are the rationales for including these hazards. Control
from a supplier such as to produce the product’s certificate of analysis (COA) or food quality
assurance program by the manufacturer is one of the preventive measures taken to prevent the
significant hazards. There is no cross-contamination risk to the facility or to other products, which
will not be controlled as high heat treatment (sauté) was used to process the hazards out of the
product.
Condiments used in the preparation of beef kurma and beef curry are sugar, salt and
tamarind peel. Microbial growth in sugar is inhibited since the chemical property of the product
is having very low water activity that inhibits microbial growth. In Petrová et al., (2015) and
Wojtczak et al. (2012), the total bacteria count of sugar were found to be low and met the
international microbiological standard. Both sugar and salt are natural anti-bacteria agents. The
chemical properties of table or cooking salt are low water activity and highly salty, inhibits the
growth of non-halophiles microbial. Therefore, biological hazards in salt can be eliminated.
Tamarind peel or asam keping biological hazard may come from post-harvest of the item itself.
Handling or storage at post-harvest is important to ensure minimal or no microbial growth and
contamination. Chemical hazards for these condiments may be carried over from the production
process or naturally present in the item.
The possible biological hazard in UHT coconut milk is microbiological survival of Bacillus
cereus spores and Staphylococcus aureus. However, these hazards were excluded because this
product undergoes ultra-high heat treatment to inactivate microorganisms and heat resistant
enzymes (Khuenpet, Jittanit, Hongha, & Pairojkul, 2016). The chemical hazards that may be
included in the hazard analysis are the presence of pesticide residue and usage of food additives.
These hazards were included because there are possibilities of pesticides usage during farming
and addition of food additives during production of UHT coconut milk that is above the specified
limit. Hence, these hazards are controlled by producing product’s certificate of analysis (COA)
which tests for pesticide residue and food additives for every batch received. As for physical
hazards, it is impossible to happen because the product goes through the hot filling piping
process into tetrapak, which does not allow penetration of dirt into the product.

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Possible hazards can also be found in packaging (stainless-steel tray and PVC plastic
wrap/stretch film). There are no identified biological hazards in both packaging materials.
However, chemical hazards were included in stainless-steel tray if the supplier provides unclean
or damaged trays. Therefore, the preventive measure is to control by cleaning and sanitation. As
for PVC plastic wrap or stretch film, the possible chemical hazard is the presence of plasticizer in
it. However, this is excluded as hazards because only food grade wrap is used. Dust is also
excluded as a physical hazard for stretch film because the film comes in rolls and the surface
facing the food are not exposed to dust.
Table 2: Frozen beef hazard analysis

4.3 Hazards related with processes and CCPs in the production process
Using the process flow diagram (Error! Reference source not found.), all potential hazards
relevant to the process of cooking chilled beef cooked in spices were identified. This also includes
the preparation process of cooking ingredients. Technical data was used as a guide to identify all
the biological, chemical and physical hazards. For each of the hazards concluded to be significant,
preventive control measures were identified to eliminate the hazard or reduce it to an acceptable
level. Preventive measures related to hygiene and good manufacturing practices (GMP), were

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included in procedures for GMP to simplify the HACCP plan. To achieve this, the process step
decision tree from MS1480:2007 was used.
There are many potential microbial hazards associated with the acceptance of raw materials
or the receiving of raw materials process. In this study, the hazard analysis for receiving process
was conducted for each ingredient as different ingredients may have different potential hazards.
Water is the main raw material used in the preparation of this dish. It is used as both for
ingredient and medium for cleaning other raw materials. As a major raw ingredient, it should
meet the provisions of Malaysia Food Regulations 1985 (Drinking water quality standards). The
biological and chemical hazards for receiving of dry items was excluded as products were handled
properly and received at the clean and chemical-free area. As for possible physical hazards at the
receiving area are the presence of dirt, dust or soil, which might be due to the use of unclean or
damaged packaging material from the supplier.
The receiving process of frozen beef may pose biological hazard if temperature control of
product is insufficient, hence will result in unacceptable microbial growth (Casaburi, Piombino,
Nychas, Villani, & Ercolini, 2015). Although the severity and likelihood of the hazard to occur at
the receiving process is significant, this step is not considered as a critical control point. From the
process step decision tree, there are control measures taken for the significant hazard that is by
ensuring the temperature of frozen beef is <-18oC upon receiving. This step does not eliminate
or reduce the occurrence of the significant hazard to an acceptable level and contamination could
not increase to unacceptable level as bacteria stays at dormant stage at very low temperature
(Leygonie, Britz, & Hoffman, 2012).
Microbial proliferation is possible in raw materials that is stored in high relative humidity dry
storage area (>70%) (Amezquita et al., 2011; Leclercq-perlat, Sicard, Trelea, Picque, & Corrieu,
2012; Tsang et al., 2018). In such an environment, there is possible growth of fungi such as
Aspergillus spp. in spices, which produces aflatoxin, thus compromise with food safety. However,
the control measures taken to prevent this from happening is by implementing storage pre-
requisite program. The stock cycle for these raw materials is by weekly. The premise will also
practice the first-in, first-out (FIFO) system. Hence, the issue of storing item for a long period in
the dry storage area should not arise.
Besides dry storage, raw material (frozen beef) were stored in the freezer with temperature
of below -18oC. Microorganisms such as Salmonella spp., E. coli, Listeria monocytogenes, and
Staphylococcus aureus may survive and grow if there is insufficient temperature control. This is
due to the increase in moisture and nutrients available when meat is exposed to high
temperature, which is consequently suitable for microbial growth (Leygonie et al., 2012). These
hazards were controlled by storing the raw material in a freezer with a temperature below -18oC
at all times.
Mis en place of the ingredients includes the unpacking or unboxing process, peeling,
thawing, washing, trimming, draining and slicing of ingredients. The hazards in these processes
(except thawing) were excluded from possible hazards, as there is good handling of products,
food handlers practice good personal hygiene, use of clean utensils, no usage of chemicals during
washing of ingredients and sealing back the packaging after usage (Dora-Liyana et al., 2018).

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These rationales will prevent the possible hazards from occurring to the raw materials
(Doménech, Amorós, Pérez-Gonzalvo, & Escriche, 2011).
The thawing process is as important as the storage process because it involves time and
temperature variables to control the growth of bacteria in the raw ingredient. If thawing was
done at room temperature, certain areas of the meat will be exposed to more favourable
temperature conditions for microbial growth since thawing took much time to melt the ice
crystals in meat (Leygonie et al., 2012; Panisello, Rooney, Quantick, & Stanwell Smith, 2000). For
this reason, good handling practices are important as a preventive measure to prevent significant
hazards from occurring. The appropriate handling is to thaw frozen meat in a chiller with
temperature between 1-10oC not exceeding 24 hours to prevent microbial spoilage (Manios &
Skandamis, 2015).
In the preparation of chilled beef cooked in spices, the meat undergoes boiling process. This
process serves to enhance the quality and safety of the meat. There are many microbial hazards
associated with the cooking of meat and the possible microbial hazards at this stage are survival
of Salmonella spp., Listeria monocytogenes, Escherichia coli, Staphyloccous aureus and Bacillus
cereus (Casaburi et al., 2015; Tewari, Singh, & Singh, 2015). The rationality to include these as
hazards are because insufficient temperature control and cooking time will result in unacceptable
microbial growth thus resulting in foodborne illness. The control measure at this process is to
cook the meat to a minimum core temperature of 70oC for more than 10 minutes (Murphy,
Martin, Duncan, Beard, & Marcy, 2004; Orta-Ramirez et al., 1997) to eliminate the biological
hazards. Since this step of process is specifically designed to eliminate the likely occurrence of
the significant hazard, this process is considered as the critical control point 1 (CCP1) (Table).
The cooking process of chilled beef cooked in spices dish starts with the heating of cooking
oil. This step is then followed by sautéing of the condiments and spices. The next step is
simmering with an addition of pre-cooked beef and coconut milk. The possible hazards during
these stages are microbial contamination from food handlers, cleaning agent residues that are
used to clean pieces of equipment and presence of foreign materials such as hair and insects.
Preventive measures to prevent the hazards are by controlling the process via process control
pre-requisite program. This includes ensuring that the cooking temperature achieves core
temperature of more than 70oC. Achieving this temperature is important as 6D log reduction of
most pathogens occurs at temperature above 70oC when cooked for more than 2 minutes (Horn,
Olsen, Hasell, & Cook, 2015; Jarvis et al., 2016; Yousif, Ashoush, Donia, & Hala Goma, 2013). The
possible hazards in sensitive raw material (frozen beef) were eliminated in the boiling process
(CCP1) before undergoing this simmering process. As a result, this process step is not critical.
The next step is packing of cooked food. During this process, food is transferred from the
cooking pot into a 4-inch stainless steel tray and later wrapped with PVC plastic wrap. Each tray
weighs approximately 5kg. Food handlers must ensure good handling practices and use clean
equipment to prevent post-handling contamination. This process is important as it protects food
against physical damage and in many cases, attack by pests and prevents contamination during
storage and distribution. The uses of PVC plastic wrap is acceptable in this situation and the
migration of plasticizer into the food is low, as the film does not have direct contact to the food
(Sekheta et al., 2010). After packing, the next step is to label the trays. Labelling is done to identify

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the product’s name, date of production, expiry date and to inform kitchen staffs on the reheating
instruction. To ensure no post-handling contamination, food handlers should practice good
personal hygiene.
Rapid chilling of these foods is the step where a food core temperature is rapidly reduced to
a safe temperature using blast chiller within certain time. This method was chosen as it is the
most effective operational step in food processes for preventing microbial growth and toxin
production after food is cooked (Choma et al., 2000). Therefore, internal food temperatures and
cooling time measurements are very important. In this study, the time and temperature critical
limits parameters were to chill food to core temperature of between 0-3oC at time between 90
to 120 minutes using blast chiller in the presence of air (Bonne, Wright, Camberou, & Boccas,
2005; James & James, 2005; Krishnamurthy & Sneed, 2011). Probe thermometer was used to
measure the core temperature of food so that it achieves <4 oC. After undergoing the process
steps decision tree, rapid chilling step is decided to be the critical control point 2 (CCP2) as shown
in Table
Chilled food is stored in the cold room food bank for a few days and made safe to be eaten.
In-house preliminary study has shown that the temperature required during storage is 0-3oC and
consumed within 4 days (96 hours), inclusive of the production day. The storage time and
temperature is in accordance with past studies related to chilled cooked foods to ensure chilled
foods is stored safely for later consumption (Carlin, 2002; Langlois et al., 1997; Man, 2008;
McClure & Amézquita, 2008; Ndraha, Hsiao, Vlajic, Yang, & Lin, 2018).
The potential biological hazards during the loading process are microbial growth where it
could occur when food is stored for a long time at inappropriate temperature. Therefore, to
prevent this from happening, the preventive measures that could be done is by ensuring cold
truck temperature is ≤4oC before loading process could take place. The cold truck temperature
must be maintained at temperature ≤4oC at all times. This is to prevent the growth of microbial
as failure to maintain the chilled condition of cold truck leads to the growth of bacteria (Ndraha
et al., 2018). The monitoring of temperature in cold truck is by using thermo-logger where it can
record the temperature during the delivery of food from centralised kitchen to satellite kitchens.
For both steps, it is not considered as a CCP since there are control measures taken to control
significant hazards from occurring at unacceptable levels.

5 Conclusion
HACCP process approach in the cook-chilled beef cooked in spices dish (beef curry and beef
kurma) control every stage of food processing. By using this approach, two CCPs has been
identified, which are the boiling of beef process and rapid chilling of the cooked dish. These two
processes have a critical limit that ensures the utmost safety for students’ consumption.

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Table 3: Hazards related to process step (boiling and rapid chilling)

Potential hazard Significance of Is this a critical control
Rationale for
biological, hazard Preventive point (CCP)?
inclusion or
chemical, measure or
Process exclusion as a
physical (B: controls applied to
step hazard (In:
Biological, C: Sev. Like Sig. prevent this Q1 Q2 Q3 Q4 CCP
Inclusion, Ex:
Chemical, P: significant hazard
Exclusion)
Physical)
B: Microbial In: Insufficient
survival temperature
(Salmonella, control and
Listeria cooking time will Cook product to a Yes
Boiling monocytogenes, result in 2 C Yes minimum of 70oC Y Y - -
E.coli, unacceptable for >10minutes. CCP1
Staphylococcus microbial growth
aureus, Bacillus and result in
cereus) foodborne illness
Ex: Cleaning agents
C: Cleaning used for cleaning
2 D No - - - - - -
agent residue equipments at
approved dosage
Ex: Visual
P: Visible foreign
inspection of all
material that
products as it is
could 4 D No - - - - - -
processed to
compromise
ensure no foreign
product safety
material is present
B: Survival of
non-spore and
spore
In: Inappropriate
performing
blast chiller time Product is cooled
pathogens
and temperature rapidly at
Rapid (Bacillus cereus, Yes
will promote 2 C Yes temperature ≤4oC Y Y - -
chilling Clostridium CCP2
microbial growth within 90 to
perfringens,
and toxin 120minutes
Listeria
production
monocytogenes,
Staphylococcus
aureus)
Ex: Cleaning agents
C: Cleaning used for cleaning
2 D No - - - - - -
chemical residue equipments at
approved dosage
Ex: Food tray is
P: Foreign wrap with stretch
material film and chilled 4 D No - - - - - -
(insects) storage is enclosed
area

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6 Acknowledgement
This study was a part of the scientific project and was funded by the Putra Siswazah
Initiative Grant (GP-IPS/2018/9620700), Universiti Putra Malaysia.

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