Did you know that keeping foods in the temperature danger zone of 41 to 135 °F (5 to 57 °C) is known as time-temperature abuse, which is a common source of foodborne illness and a major health code violation?

TCS, which stands for Time/Temperature Control for Safety, is a classification assigned to foods that are more susceptible to microbial contamination and typically have a shorter shelf life compared to others as they either naturally harbor a significant load of microorganisms from the outset or possess ideal conditions for pathogens to thrive and multiply. TCS foods are considered to be time and temperature abused at any time when they are exposed to a temperature danger zone. Food safety software and quality management systems incorporating tech-enabled integrated monitoring solutions for real-time supervision of TCS foods present a whole new level of efficiency and precision in food preservation processes and ensure food safety.

Understanding the Importance of TCS 

In food safety hazard analysis, TCS foods hold immense importance as this concept primarily revolves around maintaining these foods at a regulated temperature for a specific duration to decrease the probability of foodborne pathogen growth in the food. Since the factors affecting the shelf life of different food items vary widely, by establishing TCS guidelines for these foods, it becomes possible for food industries to effectively monitor, handle, and store them to minimize food spoilage and wastage or prevent potential foodborne illnesses. 

Let us delve into some key aspects to comprehend TCS foods.

Potentially Hazardous Foods (PHF) 

Potentially hazardous food (PHF) is defined as any food that consists in whole or in part of milk or milk products, eggs, meat, poultry, rice, fish, shellfish, edible crustacean, raw-seed sprouts, heat-treated vegetables, and vegetable products and other ingredients in a form capable of supporting rapid and progressive growth of microorganisms. TCS foods are interchangeably referred to as PHFs as well.

Source: https://www.statefoodsafety.com/Resources/Resources/time-temperature-control-for-safety-tcs-foods-poster#:~:text=TCS%20foods%20that%20are%20ready,the%20four%2Dhour%20time%20limit.

The sensitivity of these foods toward microbial proliferation is attributed to certain intrinsic characteristics: 

Moisture Content: Microorganisms require water to multiply, and moisture-rich foods offer the necessary conditions for proliferation.

pH Level: Foods with a neutral or slightly acidic pH are more vulnerable to microorganisms as pathogens can survive in this pH range more easily.

Nutritional Composition: Foods rich in nutrients, such as proteins, carbohydrates, and fats, provide a suitable food source for microorganisms as they can metabolize these nutrients to accelerate their multiplication.

Aw (Water Activity): Water activity measures the amount of water in a food product available for microbial growth, chemical reactions, and other biological and chemical processes. 

As these factors and their magnitude are dependent upon the food itself, there is only little that can be done to alter them without affecting their quality, and this is why implementing controls upon the time and temperature conditions to modify their susceptibility towards microbes is substantial.

The “Danger Zone”

Source: https://www.fsis.usda.gov/food-safety/safe-food-handling-and-preparation/food-safety-basics/danger-zone-40f-140f

Allowing food to remain at room temperature for extended periods of time can lead to the accumulation of harmful bacteria, including Staphylococcus aureus, Salmonella Enteritidis, Escherichia coli O157:H7, and Campylobacter, reaching levels that pose a health hazard. Bacteria exhibit their fastest growth within the temperature range of 40 °F to 140 °F (5°C to 60°C), doubling in numbers within as little as 20 minutes. This temperature range is commonly referred to as the “Danger Zone.” 

The following are some instructions provided by the United States Department of Agriculture’s Food Safety and Inspection Service (USDA FSIS) to keep food out of the ‘danger zone:

1. Never leave food out of refrigeration for over 2 hours. If the temperature is above 90 °F, food should not be left out for more than 1 hour.
2. ‘Keep hot food hot’—at or above 140 °F. Place cooked food in chafing dishes, preheated steam tables, warming trays, and/or slow cookers.
3. ‘Keep cold food cold—at or below 40 °F’. Place food in containers on ice.
4. Raw meat and poultry should always be cooked to a safe minimum internal temperature.
5. Foods should be reheated thoroughly to an internal temperature of 165 °F or until hot and steaming.

The appropriate management of TCS foods involves procedures to inhibit them from entering the temperature danger zone, which provides the ideal conditions for bacterial growth. Ideally, TCS foods should not be allowed to remain within the temperature danger zone for more than 2 hours, and it is advisable to use methods such as hot holding and cold holding for finished products and to store raw ingredients in a cool, dry location, diminishing the risk of contamination.

Ready-to-eat foods (RTE) are food products that require no additional cooking or preparation before consumption. Guaranteeing hazard control in ready-to-eat TCS foods highly relies on a four-hour rule, meaning that they should be either consumed or reheated/chilled for later use within a four-hour window and, if not, discarded.

Traditional Vs. Modern Methods for Keeping TCS Foods Safe

Traditional Methods

Traditional methods of controlling the time and temperature conditions of foods often depend on manual processes and conventional cooking equipment, such as stovetops, ovens, and grills. These methods require constant monitoring to ensure that food is cooked or chilled adequately and needs to be included as critical control points (CCP) or preventive control points (PCP) in the HACCP plan.

Cooling

Cooling is the process of lowering the temperature of hot cooked food to a safe range (typically from 140°F/60°C to 41°F/5°C or lower) within 2 hours or 4 hours to minimize the time it spends in the “danger zone.” Traditional cooling methods include placing hot food in shallow containers, using ice baths or cooling wands, and ensuring good air circulation in refrigerators or walk-in coolers. Cooling the foods as fast as possible is the key.

According to FDA guidelines, TCS food should undergo a specific cooling process. Within the initial two hours after cooking, it must be brought down from 135°F (57°C) to 70°F (21°C). Following this, it should continue to cool from 70°F (21°C) to 40°F (4°C) within the subsequent four hours. This cooling method is referred to as the two-stage cooling process. It is to be noted that the entire cooling procedure must be completed within a maximum time frame of 6 hours. 

Thawing

Thawing is the process of defrosting or melting frozen food to prepare it for cooking or serving. Conventional techniques encompass thawing in a refrigerator, under cold running water, or in a microwave, but never at room temperature. Refrigeration is the safest method, as it keeps the food at a safe temperature, such as 40°F (4°C) while thawing. During thawing, any pathogens that survived the processing stage or are naturally found in the ingredients could become active again and resume their biological activities. This can potentially render the food hazardous once more and introduce the chances of triggering foodborne illnesses.

Cold- and Hot-Holding

Cold-holding refers to keeping perishable food items at or below 41°F/5°C to prevent bacterial growth. This is typically done in refrigerators or cold-holding units. Hot-holding involves maintaining hot food at a temperature of 135°F/57°C or higher to stop bacterial growth. Hot-holding equipment like steam tables, warmers, or chafing dishes are used for this purpose.

Reheating/Warming

Reheating or warming is the process of heating precooked food to a safe serving temperature, usually 165°F/74°C, through stovetop heating, oven heating, or microwave heating. It is essential to ascertain that the food reaches the required temperature uniformly and the heat is equally distributed within the food product to eliminate any potential bacterial contamination.

Cooking

Cooking is the process of preparing food by applying heat to kill harmful bacteria and pathogens and make the food safe to eat through grilling, roasting, frying, boiling, and baking. Cooking times and temperatures vary depending on the type of food being cooked. 

The effectiveness of safely holding cooked TCS food at either cold or hot temperatures is based solely on the adequacy of the cooking process. If the TCS food in question does not reach its intended internal temperature during cooking, it remains a high-risk food. Utilizing a food thermometer is the only way to ensure that food has been cooked completely to the required temperature.

Continuous Temperature Monitoring

This practice involves regular and continuous monitoring of food temperatures at various stages of handling, from storage to cooking and serving, to confirm that food remains within safe temperature ranges throughout its journey from preparation to consumption. Traditionally, monitoring is done using food thermometers, temperature probes, and temperature recording logs. 

Variations in storage temperature can have a considerable impact on the safety of TCS food. To ensure the highest level of safety and meet the suggested maximum holding time, it is imperative to uphold the recommended minimum temperature for TCS food consistently.

Modern Methods

In contrast, modern methods leverage advanced food safety technology, such as sous-vide cooking machines, precision ovens, and refrigeration systems with digital controls. These technologies enable precise and consistent temperature and time management. They often include data logging and remote monitoring capabilities, making it easier for food professionals to maintain strict control over food preparation and storage processes. The following are some trending technologies available for time-temperature monitoring of foods:

IoT Sensors

Internet of Things (IoT) sensors are used to monitor temperature and humidity in real-time. These sensors are often connected to a central control system via the Internet, allowing for remote monitoring and control. If the temperature deviates from the desired range, alerts can be sent to operators or automated systems to take corrective action.

Automation and Control Systems

Innovative TCS in the food industry often relies on advanced automation and control systems. These systems use digital technology to regulate temperature, humidity, and other environmental factors within food storage facilities, refrigerated trucks, and processing plants. They can adjust settings automatically based on sensor data.

Mobile Apps

Food industry professionals can use mobile apps to monitor and control TCS remotely. They can check temperature readings, receive alerts, and adjust settings from their smartphones or tablets, providing convenience and efficiency.

RFID and NFC

Radio-frequency identification (RFID) and near-field communication (NFC) technologies are used to track individual food items or packaging containers. They can store temperature data and provide real-time information about a product’s temperature history, helping to ensure food safety.

Cloud-Based Solutions

Cloud computing allows for centralized storage and analysis of temperature data. This enables multiple stakeholders in the food supply chain to access and share information securely, making it easier to maintain temperature control standards.

Data Analytics

Data analytics and machine learning algorithms can process vast amounts of data generated by temperature sensors. This data analysis can provide insights into temperature trends, potential issues, and predictive maintenance to predict equipment failures before they occur, reducing downtime and preventing temperature control issues. 

In summary, these technologies have become essential tools for ensuring that food products are stored, transported, and processed at the right temperatures to maintain quality and safety, enhancing food safety, efficiency, and transparency throughout the supply chain.

Advantages of Tech-Enabled Control of Time-Temperature Environment of Food

In the world of food safety and quality assurance, maintaining the ideal time-temperature environment for food products is paramount. For ages, this task depended heavily on manual monitoring and paper-based record-keeping systems. However, the advent of technology has paved the way to a different outlook for controlling the time-temperature environment of food. This phenomenon has, in fact, brought forth several benefits, such as:

1. Real-Time Monitoring vs. On-Demand Monitoring

Real-time monitoring involves continuously tracking and recording the temperature conditions of food throughout its storage and handling. This is a significant advantage as it provides instant feedback and ensures that any deviations from the acceptable time-temperature range are detected immediately. Unlike on-demand monitoring, where data is collected periodically, real-time monitoring provides continuous insights into the conditions of food products. On-demand monitoring relies on sporadic checks or manual measurements, which may miss critical temperature fluctuations and can lead to food safety issues. 

2. Configuration of Acceptable and Non-Acceptable Criteria

Automated time-temperature control systems facilitate precise configuration of acceptable temperature criteria for different types of food products. This means that specific temperature ranges and time limits can be set based on the type of food, regulations, and industry standards. This customization ensures that specific requirements for each item are met, reducing the risk of spoilage or contamination due to improper temperature conditions. Non-acceptable criteria can also be defined, making it easier to identify deviations that require attention and execute remedial actions accordingly.

3. Real-time Alerts and Notifications for Non-Acceptable Criteria

Immediate alerts and notifications can be delivered to concerned parties when the temperature conditions fall outside the acceptable range or deviate from predefined criteria. These alerts can be sent to designated personnel via various communication channels, such as email or mobile apps. This timely notification enables quick intervention to address the issue, preventing foodborne illnesses and minimizing food waste.

4. Enabling Mandatory Corrective and Preventive Actions

Tech-enabled systems can facilitate the implementation of mandatory corrective and preventive actions when temperature deviations occur. These actions may include adjusting storage conditions, disposing of compromised products, or conducting sanitation procedures. Ensuring that these actions are enforced as part of standard operating procedures helps maintain food safety and quality.

5. Status Tracking of Corrective and Preventive Action Completion

Digital features such as audit logs and version control can keep a record of all corrective and preventive actions taken in response to temperature deviations. These features allow businesses to monitor the progress of these actions, ensuring they are carried out correctly and promptly. This enhances accountability and ensures that the necessary steps are completed to rectify food safety crisis situations, ultimately reducing the likelihood of recurring issues.

6. Trend Analysis of Deviations for Ongoing Enhancements

Tech-assisted systems enable businesses to conduct trend analysis of deviations over time to identify trends and patterns, which is invaluable for ongoing enhancements to food safety protocols. By analyzing historical data, companies can identify recurring issues, root causes, and patterns in temperature fluctuations. This information can guide process improvements, minimize risks, and optimize food storage and transportation practices by making informed decisions to improve their processes, equipment, and training.

As the food industry continues to evolve, embracing technology-driven solutions is not only a smart choice but also a critical step toward ensuring the safety and quality of the products we consume.

Smart Record’s Integration Features as Technology Solutions for Monitoring Time-Temperature Conditions of TCS Foods

Smart Record is a digital record-keeping software solution that can take care of the heavy lifting, automating the creation process of digital monitoring forms tailored to your specific daily food safety procedures. It streamlines and elevates the process of converting all food safety records into digital files securely stored in the cloud for enhancing food safety efforts by sending intuitive notifications to food handlers to remind them of upcoming tasks, creating an intuitive dashboard for a one-stop solution to food safety operation status, and ensuring that time-temperature monitoring for TCS foods is consistently performed on schedules. 

Smart Integration is another state-of-the-art digital solution for integrating aspects of different software modules of Smart Food Safe and connecting them with internal or external systems, such as other software or hardware products. By doing so, Smart Integration becomes a game-changer in automating the monitoring efforts necessary for safeguarding foods from time-temperature abuse by enabling the integration of surveillance and control devices or instruments with digital monitoring systems such as Smart EMP, Smart Record, and many more through technologies such as Bluetooth, Wi-Fi, Sensors, or Gateway.

Smart Record also combines the following integration features: 

Voice Integration – Smart Record includes voice integration, which enables users to supervise the handling of digital records through voice commands effortlessly, eliminating the need for manual data entry.

Bluetooth Integration – Smart Record also permits the integration with Bluetooth technology, allowing for the automatic capture of data from paired devices, sensors, or beacons.

IoT Integration – Integration with IoT-enabled devices through APIs ensures data accuracy, streamlines record management processes and provides real-time insights to support informed decision-making.

Device Library – Our expanding suite of manufacturers and devices enables users to integrate their own devices that they currently use with Smart Record, ensuring a customized experience.