Lesson 1Hazard analysis for frozen ready meals: biological, chemical, physical hazards to considerThis lesson guides you through danger check for frozen ready meals, covering germ, chem, and body dangers, their starts, badness, chance, and how finds lead to control steps and key point choices.
Process mapping for danger lookGerm dangers and grow factorsChem dangers and mix pathsBody dangers and enter pointsRisk rank: badness and chanceLinking dangers to controls and key pointsLesson 2Microbiological control program: sampling plans (ingredient, finished product), acceptance criteriaThis lesson explains how to plan a germ control program for frozen meals, including item and done product sample plans, test ways, accept rules, and how to handle bad results.
Picking goal germsSample plans for itemsDone product and area testsGerm limits and standardsSteps for bad resultsProgram look and trend checkLesson 3CCP1 — Cooking step: what can go wrong, monitoring (time/temperature probes), corrective actionsThis lesson covers the cooking step as key point 1, explaining what can fail, how to set time and cold limits, use checked probes, note results, and do fix steps when key limits miss.
Goal kill and key limitsOven and pot check studiesCore cold probe waysReal-time watch and notesHandling undercooked lotsTrend check and process betterLesson 4Quality control for sensory attributes: texture, taste, color monitoring and acceptance criteriaThis lesson explains how to set measure taste standards for frozen meals, including feel, flavor, smell, and color, and how to watch them using groups, tools, and accept rules linked to release choices.
Defining taste parts for frozen mealsReference standards and control samplesTaste group setup and trainTool color and feel measuresTaste accept limits and scoreLinking taste results to batch releaseLesson 5Portion consistency controls: checkweighers, in-line vision systems, sampling plans and correction rulesThis lesson covers ways to keep portion weights and counts steady, using weight checkers, in-line see systems, and sample plans, plus rules for fixes, rework, and notes when turns are found.
Legal and buyer weight needsWeight checker setup and checkIn-line see for portion evenSample plans and control chartsFix rules and line turnsHandling light and heavy unitsLesson 6CCP2 — Cooling/pre-freeze temperature control: risks of slow cooling, monitoring methods, corrective actionsThis lesson focuses on cooling and pre-freeze control as key point 2, explaining risks of slow cooling, goal product colds, watch tools, and fix steps when cooling curves or tool work turn.
Germ risks from slow coolingCooling paths and goal limitsBlast cooler and tunnel runCold watch and notingFix steps for slow coolingCheck of cooling key point workLesson 7Defining Critical Control Points (CCP): selection methodology and documentationThis lesson describes how to find and note key control points in frozen meal making, using danger check, choice trees, and check data to support key point pick, limits, watch, and duties.
Linking danger check to key point pickUsing key point choice trees rightChecking key point workNoting key limits and reasonGiving watch dutiesLook and recheck of key pointsLesson 8CCP3 — Metal detection/foreign body control: sensitivity settings, verification tests, response to failsThis lesson explains how to control metal and other strange bodies using metal finders and X-ray if needed, including sense set, check, usual checks, and set steps to find fails or alarms.
Risk check for strange materialsMetal finder pick and setupSense set and test piecesUsual work check testsStep to finder alarms and failsLook and stop stepsLesson 9Allergen control and cross-contact prevention: segregation, cleaning validation, labelling controlsThis lesson details allergen risk handle in frozen meal plants, including mapping allergen starts, split, checked clean, label control, and check acts to stop cross-mix and wrong label events.
Allergen mapping and risk checkSplit and special toolsAllergen change and cleanClean check and confirmLabel okay and art checksHandling recipe changes and new allergensLesson 10Record keeping, traceability and recall preparedness: batch records, supplier certificates, lot codingThis lesson details how to build strong notes and trace for frozen meals, covering batch papers, supplier certs, lot coding, and recall tests to ensure quick, aimed product pull when needed.
Must-do making and check notesSupplier okay and cert handleLot coding design and label controlTrace tests and fake recallsRecall choice trees and rolesNote keep and data true
