Lesson 1Hazard analysis for frozen ready meals: biological, chemical, physical hazards to considerThis part guides you through risk checks for frozen ready meals, covering germ, chem, and physical risks, their sources, seriousness, chance, and how results lead to control steps and key point choices in Zimbabwe.
Process mapping for risk reviewGerm risks and growth factorsChem risks and contam pathsPhysical risks and entry spotsRisk ranking by seriousness and chanceLinking risks to controls and key pointsLesson 2Microbiological control program: sampling plans (ingredient, finished product), acceptance criteriaThis part explains how to plan a germ control program for frozen meals, including ingredient and finished sampling plans, test ways, accept standards, and how to handle bad results in Zimbabwe.
Picking aim germsSampling plans for ingredientsFinished product and area testsGerm limits and standardsSteps for bad resultsProgram review and trend checksLesson 3CCP1 — Cooking step: what can go wrong, monitoring (time/temperature probes), corrective actionsThis part covers the cooking step as key control point 1, explaining what can fail, how to set time and temp limits, use checked probes, note results, and fix when limits are missed in Zimbabwe.
Aim kill and key limitsOven and pot check studiesCore temp probe waysReal-time watching and notesHandling undercooked batchesTrend checks and process boostsLesson 4Quality control for sensory attributes: texture, taste, color monitoring and acceptance criteriaThis part explains how to set clear taste standards for frozen meals, including feel, flavour, smell, and colour, and how to watch them with groups, tools, and accept standards linked to release choices in Zimbabwe.
Defining taste traits for frozen mealsReference standards and control samplesTaste group setup and trainingTool colour and feel measuresTaste accept limits and scoringLinking taste results to batch releaseLesson 5Portion consistency controls: checkweighers, in-line vision systems, sampling plans and correction rulesThis part covers ways to keep portion weights and counts steady, using weight checkers, in-line sight systems, and sampling plans, plus rules for fixes, rework, and notes when issues are found in Zimbabwe.
Legal and customer weight needsWeight checker setup and checksIn-line sight for portion evennessSampling plans and control chartsFix rules and line tweaksHandling light and heavy unitsLesson 6CCP2 — Cooling/pre-freeze temperature control: risks of slow cooling, monitoring methods, corrective actionsThis part focuses on cooling and pre-freeze control as key point 2, explaining slow cooling risks, aim product temps, watch tools, and fix steps when cooling paths or tool work go off in Zimbabwe.
Germ risks from slow coolingCooling paths and aim limitsBlast chiller and tunnel runningTemp watching and notingFix steps for slow coolingChecking cooling key point workLesson 7Defining Critical Control Points (CCP): selection methodology and documentationThis part describes how to spot and note key control points in frozen meal making, using risk checks, choice trees, and check data to back key point picks, limits, watching, and duties in Zimbabwe.
Linking risk checks to key point picksUsing key point choice trees rightChecking key point workNoting key limits and reasonsAssigning watch dutiesReview and recheck of key pointsLesson 8CCP3 — Metal detection/foreign body control: sensitivity settings, verification tests, response to failsThis part explains how to control metal and other foreign bits using metal detectors and X-ray if needed, including sense setting, checks, routine tests, and set responses to fails or alarms in Zimbabwe.
Risk check for foreign materialsMetal detector pick and layoutSense setting and test piecesRoutine work check testsResponse to detector alarms and failsCheck and prevent stepsLesson 9Allergen control and cross-contact prevention: segregation, cleaning validation, labelling controlsThis part details allergen risk handling in frozen meal plants, including mapping allergen sources, splitting, checked cleaning, label control, and check activities to stop cross-contact and wrong labelling in Zimbabwe.
Allergen mapping and risk checkSplitting and special toolsAllergen change-over and cleaningCleaning check and proofLabel okay and design checksHandling recipe changes and new allergensLesson 10Record keeping, traceability and recall preparedness: batch records, supplier certificates, lot codingThis part details how to build strong notes and tracing for frozen meals, covering batch paperwork, supplier certs, lot coding, and recall practice to ensure quick, aimed product pull-back when needed in Zimbabwe.
Must-have making and quality notesSupplier okay and cert handlingLot coding design and label controlTracing tests and fake recallsRecall choice trees and rolesNote keeping and data soundness
