01Conduct a Hazard Analysis

  • The first step in creating a HACCP plan is to conduct a thorough hazard analysis of the entire food production process. This involves identifying any biological, chemical, or physical hazards that may be present.
  • Some common hazards to consider include microbial contamination, allergens, chemical residues, foreign objects, and physical hazards such as glass or metal fragments.
  • During the hazard analysis, it is important to consider all potential sources of contamination, from raw materials to processing and packaging.
  • Document all identified hazards and their potential risks.

02Determine Critical Control Points (CCPs)

  • Once the hazards have been identified, the next step is to determine the critical control points (CCPs) in the food production process.
  • CCPs are the steps or procedures in the process where control measures can be applied to prevent, eliminate, or reduce the identified hazards to an acceptable level.
  • Typical CCPs may include steps such as cooking, cooling, chilling, fermentation, packaging, and storage.
  • It is important to prioritize the CCPs based on their significance in controlling the identified hazards.
  • Document all identified CCPs and their control measures.

03Establish Critical Limits

  • For each identified CCP, establish critical limits that must be met to ensure food safety.
  • Critical limits are criteria or values that separate acceptable from unacceptable conditions at the CCPs.
  • These limits may include factors such as temperature, time, pH level, moisture content, and others.
  • The critical limits should be based on scientific evidence and regulatory requirements.
  • Document all identified CCPs and their corresponding critical limits.

04Implement Monitoring Procedures

  • Monitoring procedures should be put in place to ensure that the critical limits are consistently met at each CCP.
  • These procedures involve regular checks and measurements to verify that the control measures are working effectively.
  • Monitoring can be done through various methods such as visual inspections, temperature recordings, product sampling, and testing.
  • Document the monitoring procedures for each CCP and the frequency of checks.
  • Any deviations from the critical limits should be recorded and corrective actions taken.

05Establish Corrective Actions

  • When a deviation from a critical limit occurs, corrective actions must be implemented immediately to address the issue.
  • Corrective actions are steps taken to identify and correct the cause of the deviation, prevent product from being released or consumed, and restore control at the CCP.
  • Examples of corrective actions include adjusting process parameters, reworking the product, disposing of contaminated product, and conducting equipment maintenance.
  • Document the corrective actions to be taken for each possible deviation.

06Establish Verification Procedures

  • Verification procedures are essential to ensure the effectiveness of the HACCP plan.
  • These procedures involve periodic reviews, audits, and inspections to verify that the plan is being followed correctly and that the control measures are working as intended.
  • Verification may include equipment calibrations, product testing, environmental monitoring, and internal or third-party audits.
  • Document the verification procedures and their frequency.

07Establish Record-Keeping Procedures

  • Accurate record-keeping is essential for maintaining the integrity of the HACCP plan and demonstrating compliance with regulations.
  • Record-keeping procedures should be established to document all relevant information related to the HACCP plan, including hazard analyses, CCPs, critical limits, monitoring records, corrective actions, and verification activities.
  • These records should be easily accessible and retained for a specified period of time.
  • Document the record-keeping procedures and retention periods.

Conclusion

By following these steps, food manufacturing companies can create a comprehensive HACCP plan to ensure the production of safe and high-quality food products. It is important to periodically review and update the plan to reflect any changes in the production process or regulations.

MethodsDetails
Step 1Conduct a thorough hazard analysis of the entire food production process.
Step 2Determine the critical control points (CCPs).
Step 3Establish critical limits for each CCP.
Step 4Implement monitoring procedures to ensure compliance with the critical limits.
Step 5Establish corrective actions for deviations from the critical limits.
Step 6Establish verification procedures to ensure the effectiveness of the HACCP plan.
Step 7Establish record-keeping procedures to maintain documentation and demonstrate compliance.
HACCP plan
food manufacturing
food safety
regulations