Section 11.7 Deli Department: Processing & Handling of Raw Poultry and Cooked Chickens

The purpose of this section is to ensure all products that are cooked on the premises, are stored, handled, processed, and displayed in a manner that does not compromise food safety or quality.

Storage

Foods to be cooked may be stored in the freezer at or below –180C, or in the coolroom at or below 5°C.

Coolroom, hot display & processing temperatures are monitored by delicatessen staff and recorded on the relevant check sheet.

Processing & Handling of Cooked Chickens

Different size chickens are placed on separate trays and displayed separately as large and small.

Free range are keep separated and are identified by a green coloured leg tie.

Fresh chickens are placed on the stainless-steel racks or skewers (whichever is applicable) and placed into the oven or rotisserie.
The quantity of chickens cooked at once is determined as per store requirement.

Oven settings are usually pre-set on newer models, but all staff should be familiar with each program or cook setting.

The chickens then are allowed to cook until the cycle is complete, and the oven gives a buzzer sound. Once cooked, the rack is removed and allowed to stand for up to 1 minute.

The cooked chickens are then carefully but immediately placed in the hot foods display or Bain Marie. The use of stainless-steel tongs and a non-porous approved safety glove are to be used when handling the cooked food. recommended.

Chickens that are bagged up for the stand alone (Grab and Go) displays are to be marked with the time they were cooked.

Temperature Checking of Chickens

The core temperature of a chicken cook is taken by inserting a clean, dry, sanitised probe thermometer into the thickest part of the breast of one chicken upon removing the rack / skewer from the oven and waiting for the temperature to peak, whilst unloading the other chickens into the hot display or bag. The highest core temperature attained is recorded.

NOTE: Food legislation stipulates that the minimum internal cook temperature of all hot foods is 74°C. If this has not been attained, the cook is to be extended until this is attained, otherwise the food is to be dumped.

A chicken is sufficiently cooked when its internal temperature has reached at least 740C or when the juices of the chicken run clear when the chicken is pierced between the breast & the leg. Generally, a good, even cook will have the wings still moist and the core temperature around 95-1000. The cook temperature setting should be lowered & time is to be increased if this is not the case.

If equipment failure prevents the chicken core temperature from reaching 750C then the Manager is notified, and the chickens are dumped. A service is call is made immediately.

Hot Foods Display

The hot display must be switched on first thing in the morning and the trays placed inside to ensure that they will preheat to greater than 60°C by the time hot food is ready to be loaded. The normal thermostat setting for this is 95 for the unit.

The temperature of the chickens are taken several times throughout the day by inserting a calibrated probe thermometer and recording it on the relevant check sheet.

All temperature checks should indicate that the foods are displayed at or above 600C at all times.

Generally, the temperature should not exceed 650C (if at all possible) as well, as this will shorten the shelf life of hot foods in the Baine Marie or the Grab and Go display.

Temperature checks on chickens should be taken when the cook is finished, before midday or at least 2 hours after the first cook, and during the last hour of trading. No other products in the hot display need to be temperature checked if chickens are checked.

All Chicken cooked during trading should be sold within four (4) hours – any products remaining after 4 hours should be actioned and documented on Form 26. This is a recommended standard.

Any products remaining after 2 hours should be actioned and documented on Form 26 with a maximum time on show not to exceed 4 hours.

The temp of cooked small goods to be documented on Form 26.

Any unsold take-away foods are either marked down, dumped at the end of that day’s trading & these quantities are recorded.

When it is obvious any whole cooked chickens remaining are not going to be sold by the end of the day’s trading they are to be either:

Marked down at the discretion of the relevant Manager until sold Dumped, or Removed from display at or above 600C and further processed as per cooling procedure.

Further Processing & Cooling of Hot Chickens (options)

General Instruction
Any further processing of whole chickens at the end of the day’s trading must be done in a hygienic and controlled manner to ensure that the quality and safety of the chicken will not be compromised. The use of clean, dry disposable gloves is essential in this process and once the operation has started, must not be interrupted until completed.
The Deli Manager is responsible for periodically monitoring and validating the temperature of the chicken every 12 months to ensure that it will cool within the following temperatures and times:
Greater than 600C to 210C in less than 2 hours, and,
210C to less than 50C in less than 4 hours to ensure that the cooling of the food complies to national food safety laws. Selling whole cold chickens is not a Drakes practice.

To ensure this occurs the following options are used:
Option 1: Sale of Boneless, Skinless Chicken Meat

  • The breast, leg and thigh meat are hygienically and carefully removed from the bone, ensuring no skin, bone or gristle are included. The rest of the chicken is dumped.
  • The chicken meat is placed in a clean, dry tray until filled, or for a maximum time of 20 min. (whichever comes first).
  • The tray of chicken meat is marked with a day-dot sticker, or a use by date (24 hrs), the tray is completely stretch sealed and immediately placed into the coolroom.
  • The process is repeated for the next tray of chicken meat (if applicable).
  • Next day the meat is removed from the coolroom and placed into an appropriate position in the service display & sold at a premium price at the discretion of the relevant Manager.
  • The shelf life of the chicken meat is no longer than 24 hours from the time it is removed from the hot display (using clean disposable gloves) and cooled

Option 2:
The first four points in option 1 (above) are followed, then, Next day the meat is removed from the coolroom and used as an ingredient for, salads and sandwiches, rolls and chicken and gravy packs.

Form 37 Cooling Validation Form
The below form is an example for the time and temperature validation for the product chill process.

Time and Temperature Validation for Product Chill Process Process Operation: Chicken
Premises: Rochedale
Date: 19 / 11 / 2019

 

  Time Temperature    
Stage 1

 

Time and Temperature of product at commencement of cooling procedure.

(Chicken has been held in hot box for 4 hours.)

  12.30pm 60˚or greater

 

  

Method used:

 

Thermometer/Probe

Should equal temp at hot box

 Chill in cool room- under fans or coolest section-

cut chickens in half prior to placing in coolroom.
Stage 2

 

Time and Temperature of product @ 2 hrs.

 2.30pm 21º

 

 Method used:

 

Thermometer/Probe

 Record time and temp Within 2 hours of stage 1 commencement time.

Required time frames

60º – 21º in less than 2 hours.
Stage 3

 

Time and Temperature of product @4hrs.

 4.30pm 10º  

Method used:

 

Thermometer/probe

 Record time and temp Within 2 hours of stage 2 commencement time.

Required time frames 21º – 5ºin less than 4 hours
Final Stage

 

Time and temperature at completion of cooling procedure

 6.30pm Under 5˚  

Method used:

 

Thermometer/probe

 Can be now shredded and sold with 24hrs.

The completed process confirms that all cook/chill steps of the HACCP plan for this product were accurately and truthfully validated and complied with AS 4696:2002 Cooked Product Cooling protocols.
Completed By:_________________________________________________________ Date: ______ / ______ /______________

Processing & Handling of Raw Poultry

Fresh chicken is prepared and displayed on designated and separated bench space. Only used for raw poultry.

  • Ensure all items are clean and sanitized before processing.
  • Clean the bench space after each time used.
  • When you stop or go for a break ensure all items are cleaned off and sanitized as bacteria builds up during the day.
  • All products must be kept <5°. Take temperature and record as required to ensure < 5° is always being achieved.
  • Only work with one crate of birds at a time/ one carton of meat at a time.
  • Empty all boned products into bins in cool room each time a new crate is taken.
  • If any products are dropped onto a non-food contact surface e.g. – floor, the product must be disposed of into the rubbish bin and never be used as a food grade product.
  • Only take enough poultry/meat to complete product make up within 20 minutes. Display and serving requirements of Raw poultry.
  • Poultry area is to be used for poultry area only.
  • Raw and cooked products to be kept separate.
  • When serving use tongs, disposable gloves or hand in inverted bag.
  • Tong dispensers to be filled with sanitizer and emptied, cleaned and refilled 3 hourly.
  • Where possible designate one scale for all raw poultry. Do not use for any other products.
  • Poultry scales to be wiped down and sanitize whenever soiled by any poultry blood or juice.
  • Doors must be kept closed to maintain maximum wholesomeness and temperatures.
  • Ensure you document the sanitiser changes on Form 26

      • At the end of each day all poultry products are stretch wrapped and placed in the coolroom. The product is re-bowled before being placed in the case the following day.