Last Updated on March 14, 2024 by Ossian Muscad
Did you know that one in six Americans will get sick from foodborne illness each year? That’s a lot of people! So, to reduce the chances of your business becoming one of them, you should create and implement a HACCP plan. But what is a HACCP plan, and how do you make one? Don’t worry; we’re here to help! This article will discuss the importance of using a HACCP plan and why you should use one. We’ll also provide helpful tips on creating and implementing your HACCP plan.
What is HACCP?
Hazard Analysis and Critical Control Point (HACCP) is a systematic, preventive approach designed to ensure food safety from environmental, chemical, and biological hazards. By identifying potential hazards in the food production process, HACCP allows businesses to take precise steps to eliminate or reduce the risk of these hazards to an acceptable level. It provides businesses with a structured method to assess their food processing operations and pinpoint where problems might occur.
The primary goal of HACCP is to prevent hazards rather than trying to detect food contamination after it has happened, making it an integral part of regulatory compliance and consumer safety in the food industry.
Brief History of HACCP
The origins of the Hazard Analysis and Critical Control Point (HACCP) system can be traced back to the 1960s when it was first developed by NASA (National Aeronautics and Space Administration) and a group of food safety specialists. The primary goal was to ensure the safety of food for astronauts heading into space, necessitating a method that could prevent foodborne illness. Given the critical nature of space missions, the system was designed to identify potential hazards and control them before they could pose a risk to astronauts’ health.
In the following decade, recognizing the effectiveness and preventive nature of the HACCP system, the United States Food and Drug Administration (FDA) began incorporating its principles into food safety regulations, particularly for low-acid canned foods. This adoption marked the beginning of HACCP’s broader application beyond space missions to various sectors within the food industry.
Today, HACCP is acknowledged globally as a fundamental food safety tool. It is supported and promoted by major international organizations such as the Codex Alimentarius Commission (jointly run by the FAO and WHO), reinforcing its utility and efficacy in preventing foodborne illnesses worldwide.
What is a HACCP Plan?
A HACCP Plan is a written document based on the principles of the Hazard Analysis and Critical Control Point system. It depicts the procedures a company follows to ensure the safety of its food products. It outlines the possible hazards associated with each step of the production process, from raw materials to handling and distribution.
The plan specifies the measures for hazard control, the methods of monitoring these controls, corrective actions to be taken when monitoring indicates a potential hazard, and records to verify the system’s ongoing effectiveness.
HACCP is a proactive approach designed to prevent potential food safety issues rather than reacting to them after the event. Consequently, a well-implemented HACCP Plan is an invaluable tool in the prevention of foodborne illness.
The 4 Categories of Food Hazards
Before we discuss the steps of developing an HACCP plan, let’s first talk about food hazards. What are they? A food hazard is any biological, chemical, or physical agent that has the potential to contaminate food and cause illness or injury.
Food hazards are introduced to the food supply anytime via harvesting, storage, formulation, preparation, packaging, labeling, and serving. There are four main categories of food hazards:
- Biological Hazards: This category refers to food contamination from harmful microorganisms (e.g., bacteria, viruses, parasites). These microorganisms can cause foodborne illnesses and are commonly found in raw meat, poultry, seafood, and unpasteurized dairy products.
- Chemical Hazards: This category refers to contamination from chemical substances (e.g., cleaning products, pesticides, and natural chemicals like mycotoxins). Chemical hazards can result from improper use of chemicals in food processing or storage, leading to potential health risks for consumers.
- Physical Hazards: This category refers to food contamination brought by foreign objects or items that aren’t normally part of the food (e.g., glass, plastic, wood, metal fragments). If consumed accidentally, these physical hazards can pose a choking hazard or cause injuries.
- Allergens: This category refers to contamination brought by the presence of food allergens (e.g., peanuts, milk, soybeans, eggs, crustacean shellfish, tree nuts, and wheat). Allergen contamination can trigger allergic reactions in individuals with food allergies, emphasizing the importance of proper labeling and handling of allergenic ingredients.
7 HACCP Principles
HACCP consists of seven formal principles that provide the framework for developing and implementing a HACCP Plan. Understanding these principles is essential for anyone involved in food production and safety. By segmenting your HACCP plan, you can effectively address all potential hazards and implement control measures to prevent or eliminate them. The seven HACCP principles are:
Hazard Analysis
Hazard analysis requires managers to identify and evaluate potential hazards in their food production process. This involves conducting a thorough analysis of all stages of the food supply chain, from raw material acquisition to distribution and consumption. Time/Temperature Controlled for Safety (TCS) foods are often identified as priority foods for their potential to support pathogen growth and cause foodborne illnesses. Factors that can lead to hazards include biological, chemical, or physical agents at any stage of production. Common examples of foods or processes included in a hazard analysis are:
- Serving foods that don’t need cooking (e.g., salad, fruit, cold cuts, cheese)
- Cooking foods for immediate consumption (e.g., grilled meat, cooked vegetables)
- Sauces, chilis, and soups that are prepped, cooked, cooled, reheated, and served
- Foods that are prepped and stored (e.g., coleslaw, potato salad, dips)
Example: Raw chicken breast is typically prepared, grilled, and consumed on the same day. The critical issue with chicken lies in the possibility of bacteria contaminating the final dish if it is not cooked thoroughly. Bacteria pose a significant biological risk.
Determine Critical Control Points
Critical Control Points (CCPs) are specific points in the food production process where control procedures can be applied to prevent, eliminate, or reduce hazards to an acceptable level. CCPs are determined during the hazard analysis and are essential in managing hazards and ensuring food safety. To minimize risk, each CCP should be monitored and controlled regularly.
Regular monitoring helps ensure that the CCP is under control and that any deviation from the critical limit is promptly corrected. Documentation is crucial to any HACCP plan as it provides evidence of monitoring, corrective actions, and verification. Here’s a list of common critical control points of a commercial kitchen:
- Receiving food from your supplier
- Storing food at the appropriate temperature
- Preparing and cooking food to safe temperatures
- Cooling cooked food quickly before storing it in the refrigerator
- Cooking and reheating food properly
- Holding and serving food at safe temperatures
- Holding hot or cold food for extended periods before serving
Example: Cooking raw chicken breast is the critical step for eliminating or reducing bacteria to a safe consumption level. Hence, cooking raw chicken is classified as a Critical Control Point (CCP).
Establish Critical Limits
Establishing critical limits involves setting specific parameters that must be met to ensure food safety. Critical limits are usually set for each CCP and serve as a guide for measuring whether a process is under control or not. They should be quantifiable, measurable, and observable. Establishing critical limits is crucial, as it helps prevent food safety risks from occurring. Examples of measurable critical limits include:
- Time
- Temperature
- Water activity
- pH Level
- Weight
- Dimensions (e.g., thickness of meat)
Example: Raw chicken breast must reach an internal temperature of 165 degrees Fahrenheit for at least 15 seconds to effectively eliminate bacteria. Achieving this critical limit ensures food safety. Cooking the chicken breast on the grill for the recommended duration will meet this essential requirement.
Establish Monitoring Procedures
Monitoring procedures offer immediate insight into the Critical Control Points (CCPs) outlined in your HACCP plan. They should meet your establishment’s specific needs, be easy to understand and carry out, and provide accurate data. This may involve using appropriate tools, such as thermometers and timers. Regular monitoring is essential for identifying potential problems before they arise and implementing corrective actions promptly.
Assigning monitoring responsibilities to trained staff can help ensure that monitoring is carried out correctly and consistently. Training should also include instructions on how to document all necessary information, such as critical limits, deviations from those limits, and corrective actions taken. These staff members, which feature restaurant managers, chefs, and kitchen staff, are accountable for managing the critical control points in your HACCP plan.
Example: For accurate monitoring of the chicken, employ a clean, sanitized probe thermometer to measure the temperature at the thickest part of the chicken breast. Ensure that every piece of grilled chicken reaches a minimum internal temperature of 165 degrees Fahrenheit for at least 15 seconds.
Establish Corrective Actions
Deviations are critical limits that have not been met, and corrective actions must be taken promptly to ensure food safety. Establishing a plan for correcting deviations is critical in maintaining control of your CCPs. This may involve identifying potential causes of deviation, such as improperly calibrated equipment or inadequate training, and taking appropriate steps to address them immediately. The action should be immediate and preventive, and the CCP should be monitored further to ensure that it is back under control.
Immediate corrective actions are taken as soon as a deviation from a critical limit is identified, ensuring that no unsafe product is released. These actions are direct responses to problems that occur during the food production process and are aimed at rectifying the situation quickly to safeguard food safety. Examples of immediate corrective actions include:
- Discarding food that does not meet the required safety standards.
- Re-cooking food that has not reached the safe internal temperature.
- Immediately recalibrating or repairing malfunctioning cooking equipment.
On the other hand, preventive and corrective actions are implemented to prevent the recurrence of the deviation. These actions involve analyzing the root causes of the deviations and introducing changes to the process, protocols, or systems to ensure the issue does not arise again. Examples of preventive corrective actions include:
- Revising cooking procedures to ensure consistent achievement of safe temperatures.
- Implementing a more robust training program for kitchen staff on food safety practices.
- Upgrading or replacing consistently malfunctioning equipment to avoid future deviations.
Both immediate and preventive corrective actions are vital components of an effective Hazard Analysis and Critical Control Points (HACCP) plan. They ensure not only that immediate threats to food safety are addressed but also that long-term solutions are put in place to maintain high standards of food safety.
Example: If the chicken breast does not reach the required temperature after checking with a thermometer, despite cooking it for the correct duration, it should be cooked further until it reaches 165 degrees Fahrenheit for 15 seconds. Remember to note down this extra cooking time.
Establish Verification Procedures
To ensure the effectiveness of your HACCP plan, it is essential to verify that all control measures are consistently being met and are working effectively. Verification procedures involve regularly reviewing critical limits, monitoring records, corrective action plans, and food safety training protocols. This process ensures that the HACCP plan remains relevant and current in preventing food safety issues. Examples of verification procedures that you can use in your establishment include:
- Reviewing records and logs for CCP monitoring procedures and corrective actions taken.
- Conducting internal audits to evaluate the effectiveness of current food safety practices.
- Having a third-party audit your HACCP plan to ensure compliance with regulatory requirements.
- Performing training evaluations to ensure all staff members are up-to-date with food safety protocols.
Example: A manager may review temperature monitoring charts after each shift change to verify that critical limits for chicken breast have been adhered to. Analyzing the recorded temperatures can assist your staff in recognizing patterns and adjusting their procedures to mitigate potential risks in the future.
Recordkeeping and Documentation
Keeping accurate records allows you to stay on top of your HACCP plan, track potential issues, and demonstrate compliance with food safety regulations. Ensure that all monitoring records are complete and accurate and include detailed information about the critical limits, deviations, and corrective actions taken.
Records should also be clearly labeled and stored in a secure location for future reference. In addition, train employees so that they know the importance of recordkeeping and understand how to accurately complete all required documentation. Notable records that are kept about a HACCP plan include:
- Logs of correction action
- Time and temperature logs
- Maintenance records for equipment
- Employee training records
- Standard operating procedures for each CCP
- Calibration logs for equipment used in monitoring critical limits
- Supplier verification records
- Workplace forms and checklists
- Complaints, recall, or food safety incident reports
Example: Temperature monitoring charts, records of corrective actions, and chicken invoices are retained for six months, while grill specification sheets and maintenance logs are stored for a year. This data serves as crucial support for verifying the HACCP plan should any issues arise.
What is HACCP Certification?
HACCP Certification is an essential hallmark of excellence in food safety. This certification signifies that a company adheres to the highest standards of food safety, meeting the rigorous requirements set by food safety authorities. Obtaining an HACCP certification implies that a business is committed to maintaining a safe food supply chain, from production to serving, thereby ensuring the safety and well-being of its customers.
Acquiring HACCP certification involves a comprehensive review of the company’s food safety processes, including hazard analysis, identification of critical control points, and the establishment of preventive measures against food safety hazards. While larger food entities like manufacturers, processors, and distributors are generally mandated to possess this certification, it’s less common among smaller businesses such as independent restaurants.
For them, the focus might be more on applying HACCP principles rather than obtaining formal certification. This approach allows companies of all sizes to ensure the integrity of their food safety practices, promoting consumer confidence and regulatory compliance.
How to Get HACCP Certification?
As with any other certification, obtaining HACCP certification involves a series of well-defined steps that ensure your food service or production business meets the rigorous standards for food safety. This process is not only a demonstration of your commitment to maintaining high levels of hygiene and safety. Still, it is also a critical measure in building trust with consumers and regulatory bodies. To successfully achieve HACCP certification, companies must undertake the following key actions:
- Complete Training Courses: Essential for anyone involved in the HACCP plan, these courses provide a comprehensive understanding of how to identify, evaluate, and control food safety hazards.
- Contact an NSF Auditor: NSF International is a globally recognized public health and safety organization. Contacting an NSF-certified auditor can help guide you through the process of achieving HACCP certification.
- Onsite Visit: An essential step where the auditor assesses the onsite implementation of HACCP principles, ensuring that all practices and procedures meet the required standards.
- Off-Site Visit: It is sometimes necessary for the auditor to review additional documentation and records that are not readily available during the onsite visit or to assess suppliers and external parties involved in the food supply chain.
- Continuous Monitoring and Improvement: After initial certification, regular monitoring and updates to the HACCP plan are crucial. This ongoing process ensures that the food safety management system remains effective and compliant with any changes in regulations or operations.
Essential Terms to Know
Understanding HACCP terminology is a fundamental step toward implementing a robust food safety management system. Below is a list of key terms essential for anyone engaged in the HACCP process and their accurate definitions:
- Biological Contaminant: Microorganisms such as bacteria, viruses, fungi, and parasites that can cause foodborne illness if present in food.
- Chemical Contaminant: Substances that can cause harm if ingested, including pesticides, food additives, cleaning agents, and toxins, which might contaminate food during the production, processing, or storage stages.
- Corrective Action: Procedures that need to be taken when the monitoring indicates that a particular CCP is not under control. These actions aim to correct the issue and prevent the occurrence of a hazard.
- Hazard: A biological, chemical, or physical agent that has the potential to cause illness or injury in the absence of its control.
- Monitor The act of conducting a planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verification.
- Physical Contaminant: Foreign materials in food that can cause harm when ingested, such as glass shards, metal fragments, or even bone chips.
- TCS Food: Time/Temperature Control for Safety Food refers to foods that require specific time and temperature conditions to prevent the growth of microorganisms and the production of toxins.
- Critical Control Point (CCP): A step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
- Validation: The process of demonstrating that the HACCP plan as a whole or in part is effective in controlling the identified hazards to the desired level of assurance.
Frequently Asked Questions (FAQs)
Q1: How long does HACCP certification last?
HACCP certifications are subject to regular audits to verify continuous adherence to the HACCP plan. These audits ensure that a business maintains the high standards of food safety set forth by its initial certification. Typically, these audits are conducted on an annual basis, but the frequency can vary depending on the specific requirements of your certification body. Businesses must prepare for and actively participate in these audits to sustain their certification status and continue demonstrating their commitment to food safety.
Q2: How long does it take to get HACCP certified?
The time frame for obtaining HACCP certification can vary depending on factors such as the size and complexity of your business, current food safety practices, and the responsiveness of your team in implementing necessary changes. Generally, the process takes between 3-6 months from the initial assessment to full HACCP certification. This time frame can be reduced for businesses that already have robust food safety management systems in place.
Q3: Can a business lose its HACCP certification?
Yes, businesses can lose their HACCP certification if they fail to comply with the standards set forth by their certification body. This can occur due to non-compliance during audits or failure to make necessary improvements and updates to the HACCP plan. Businesses must maintain strict adherence to food safety practices and continuously monitor and improve their systems to avoid losing their certification status.
Q4: Can a HACCP plan be modified or updated?
Yes, an HACCP plan can and should be regularly modified and updated to reflect any changes in operations, regulations, or new hazards that may arise. Businesses need to have a system in place to monitor and update their HACCP plan and ensure continuous compliance with food safety standards.
Q5: What are the benefits of being HACCP certified?
Obtaining HACCP certification can bring several benefits to a business, including:
- Enhanced food safety practices and reduced risk of foodborne illness
- Improved compliance with regulations and industry standards
- Increased consumer confidence in the safety of your products
- Better access to markets and potential business opportunities that require HACCP certification as a prerequisite. Overall, HACCP certification demonstrates a business’s commitment to food safety and can improve its reputation and competitiveness in the market.
Q6: Is HACCP certification mandatory?
HACCP certification is not mandatory for all businesses, but certain regulatory bodies or industry standards may require it. For example, the Food Safety Modernization Act (FSMA) in the United States requires HACCP plans for most food facilities. Additionally, many retailers and food service providers may require their suppliers to have HACCP certification. Businesses must research their specific industry requirements and assess whether obtaining HACCP certification is necessary for their operations.
Streamline the HACCP Process with DATAMYTE
DATAMYTE is a quality management platform with low-code capabilities. Our Digital Clipboard, in particular, is a low-code workflow automation software that features a workflow, checklist, and smart form builder. This tool lets you create custom checklists for food safety audits and inspections. Our platform also supports barcode scanning, real-time notifications, automatic data capture, and reporting features to ensure a smooth HACCP process.
DATAMYTE also lets you conduct layered process audits, a high-frequency evaluation of critical process steps, focusing on areas with the highest failure risk or non-compliance. Conducting LPA with DATAMYTE lets you effectively identify and correct potential defects before they become major quality issues.
With DATAMYTE, you have an all-in-one solution for streamlining your HACCP process, ensuring compliance with regulations and industry standards, and maintaining the highest level of food safety for your customers. Book a demo now to learn more.
Conclusion
By adhering to the guidelines outlined in a HACCP plan, businesses can significantly mitigate risks associated with food safety, ensuring their products are safe for consumption. HACCP certification not only enables compliance with regulatory requirements but also enhances operational efficiency and consumer confidence. It’s a proactive approach, emphasizing prevention rather than remediation of food safety issues.
For any business in the food industry, investing in HACCP certification is an investment in its future, safeguarding its reputation, customer trust, and, ultimately, its success in a competitive market. Regular updates and audits of the HACCP plan ensure continued compliance and improvement, fostering a culture of quality and safety that benefits everyone, from the producer to the end consumer.
