These are described in Principle 6. It consists of two activities. This requires on-site work. Second, validation uses scientific and technical principles to identify whether the HACCP plan offers the control needed for identified hazards.
Both the frequency and method should appear in the plan. Verification and validation are important for all businesses, but they become critical for those monitored by governments. For example, if you run a meat or poultry operation under the purview of the USDA, then you will find that USDA inspectors run some verification activities.
Both programs are required by the USDA. Finally, identify the required records and create systems that keep them up to date Principle 7. Both your team and regulators require this. Without consistent paper or digital logs , you lose critical information regarding your product and, if a deviation leads to consequences, you may be subject to penalties. To wrap everything up, bundle your HACCP plan template with the other documents relevant to your system:.
Then, it will be easy to read, complete, and keep updated. Each record should also identify the person in charge of that record. These are critical for regulatory compliance and certification. Modifications should be made to the flow diagram as necessary and documented.
After addressing the preliminary tasks discussed above, the HACCP team conducts a hazard analysis and identifies appropriate control measures. The purpose of the hazard analysis is to develop a list of hazards which are of such significance that they are reasonably likely to cause injury or illness if not effectively controlled. Hazards that are not reasonably likely to occur would not require further consideration within a HACCP plan.
It is important to consider in the hazard analysis the ingredients and raw materials, each step in the process, product storage and distribution, and final preparation and use by the consumer.
When conducting a hazard analysis, safety concerns must be differentiated from quality concerns. A hazard is defined as a biological, chemical or physical agent that is reasonably likely to cause illness or injury in the absence of its control. Thus, the word hazard as used in this document is limited to safety. If the hazard analysis is not done correctly and the hazards warranting control within the HACCP system are not identified, the plan will not be effective regardless of how well it is followed.
The hazard analysis and identification of associated control measures accomplish three objectives: Those hazards and associated control measures are identified. The analysis may identify needed modifications to a process or product so that product safety is further assured or improved. The analysis provides a basis for determining CCPs in Principle 2. The process of conducting a hazard analysis involves two stages.
The first, hazard identification, can be regarded as a brain storming session. During this stage, the HACCP team reviews the ingredients used in the product, the activities conducted at each step in the process and the equipment used, the final product and its method of storage and distribution, and the intended use and consumers of the product.
Based on this review, the team develops a list of potential biological, chemical or physical hazards which may be introduced, increased, or controlled at each step in the production process. Appendix C lists examples of questions that may be helpful to consider when identifying potential hazards. Hazard identification focuses on developing a list of potential hazards associated with each process step under direct control of the food operation.
A knowledge of any adverse health-related events historically associated with the product will be of value in this exercise. After the list of potential hazards is assembled, stage two, the hazard evaluation, is conducted. During this stage, each potential hazard is evaluated based on the severity of the potential hazard and its likely occurrence. Severity is the seriousness of the consequences of exposure to the hazard.
Considerations of severity e. Consideration of the likely occurrence is usually based upon a combination of experience, epidemiological data, and information in the technical literature.
When conducting the hazard evaluation, it is helpful to consider the likelihood of exposure and severity of the potential consequences if the hazard is not properly controlled. In addition, consideration should be given to the effects of short term as well as long term exposure to the potential hazard. During the evaluation of each potential hazard, the food, its method of preparation, transportation, storage and persons likely to consume the product should be considered to determine how each of these factors may influence the likely occurrence and severity of the hazard being controlled.
The team must consider the influence of likely procedures for food preparation and storage and whether the intended consumers are susceptible to a potential hazard. However, there may be differences of opinion, even among experts, as to the likely occurrence and severity of a hazard. Hazards identified in one operation or facility may not be significant in another operation producing the same or a similar product. A summary of the HACCP team deliberations and the rationale developed during the hazard analysis should be kept for future reference.
This information will be useful during future reviews and updates of the hazard analysis and the HACCP plan. Appendix D gives three examples of using a logic sequence in conducting a hazard analysis. While these examples relate to biological hazards, chemical and physical hazards are equally important to consider. Appendix D is for illustration purposes to further explain the stages of hazard analysis for identifying hazards.
Hazard identification and evaluation as outlined in Appendix D may eventually be assisted by biological risk assessments as they become available. While the process and output of a risk assessment NACMCF, 1 is significantly different from a hazard analysis, the identification of hazards of concern and the hazard evaluation may be facilitated by information from risk assessments.
Thus, as risk assessments addressing specific hazards or control factors become available, the HACCP team should take these into consideration.
Upon completion of the hazard analysis, the hazards associated with each step in the production of the food should be listed along with any measure s that are used to control the hazard s. The term control measure is used because not all hazards can be prevented, but virtually all can be controlled.
More than one control measure may be required for a specific hazard. On the other hand, more than one hazard may be addressed by a specific control measure e. For example, if a HACCP team were to conduct a hazard analysis for the production of frozen cooked beef patties Appendices B and D , enteric pathogens e.
Cooking is a control measure which can be used to eliminate these hazards. The following is an excerpt from a hazard analysis summary table for this product.
Enteric pathogens: e. The hazard analysis summary could be presented in several different ways. One format is a table such as the one given above. Another could be a narrative summary of the HACCP team's hazard analysis considerations and a summary table listing only the hazards and associated control measures.
A critical control point is defined as 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. The potential hazards that are reasonably likely to cause illness or injury in the absence of their control must be addressed in determining CCPs.
Complete and accurate identification of CCPs is fundamental to controlling food safety hazards. A CCP decision tree is not a substitute for expert knowledge.
Critical control points are located at any step where hazards can be either prevented, eliminated, or reduced to acceptable levels. Examples of CCPs may include: thermal processing, chilling, testing ingredients for chemical residues, product formulation control, and testing product for metal contaminants. CCPs must be carefully developed and documented. In addition, they must be used only for purposes of product safety. For example, a specified heat process, at a given time and temperature designed to destroy a specific microbiological pathogen, could be a CCP.
Likewise, refrigeration of a precooked food to prevent hazardous microorganisms from multiplying, or the adjustment of a food to a pH necessary to prevent toxin formation could also be CCPs. Different facilities preparing similar food items can differ in the hazards identified and the steps which are CCPs.
This can be due to differences in each facility's layout, equipment, selection of ingredients, processes employed, etc. A critical limit is used to distinguish between safe and unsafe operating conditions at a CCP. Critical limits should not be confused with operational limits which are established for reasons other than food safety.
Each CCP will have one or more control measures to assure that the identified hazards are prevented, eliminated or reduced to acceptable levels. Each control measure has one or more associated critical limits. Critical limits may be based upon factors such as: temperature, time, physical dimensions, humidity, moisture level, water activity a w , pH, titratable acidity, salt concentration, available chlorine, viscosity, preservatives, or sensory information such as aroma and visual appearance.
Critical limits must be scientifically based. For each CCP, there is at least one criterion for food safety that is to be met. To ensure your food temperature logs are accurate, calibrate your thermometers regularly. Use the following log to monitor the effectiveness of your thermometers. If you are under FDA jurisdiction, you must review your plan at least once every three years.
Spending weeks creating your compliance documents will cost you a lot. A HACCP plan aims to help you control any potential biological, physical, and chemical hazards that can contaminate your food products and create unsafe food for your consumers. This document is a description of all food safety concerns and practices in your establishment. Every food facility, especially foodservice operations and production companies, requires its own HACCP plan. These plans can be very specific for each finished product or food production process that they need separate HACCP plans.
The presence of the HACCP plan and its compliance with the law is audited by the health department at least once a year in the food industry. Here, it's important to keep in mind that the HACCP plan is not meant for your regulatory agency, but for your own sake and for your customers. It is there to keep your food on a safe level. With a template, there is no need to blindly put information that will not add to the value of your plan.
It's not a pleasant thought, but imagine if something happens with any of your customers. The financial loss can be something that you as a business owner won't survive. It's always better to set up a strong HACCP system at the beginning of your business , with rules that are easy to follow. If your employees understand why they have to comply with certain rules, they will be more willing to do so. As a result, the food is always safe to eat for your customers.
A HACCP team is an essential part of a food business that is responsible for composing and updating your food safety management system and takes control of food safety. The members of a HACCP team should have a strong sense of ownership and commitment to food safety because it is one of the most important things in the food industry businesses.
Your team should be well aware of all food handling practices related to your business. These practices must also include any potential food safety hazard to prevent the loss of control and relevant continuous monitoring procedures to establish the control of food safety. All members must also have good and accurate record-keeping skills to serve as tracking documents in case of deviations from standards for future verification. Also, note that the food industry has one of the highest levels of employee mobility.
This means that the HACCP team has to consider the fact that employees, who are responsible for food safety on a daily basis, have to be constantly trained.
This task can be a real challenge if your team consists of tens or even hundreds of people. In this case, assign a person, who is responsible for training them and try to find a solution or a tool how to help him.
It is important that you keep your company's HACCP plan up-to-date , make a copy of it, and even better if you have a digital food safety management together with a HACCP plan in place.
Keeping a digital food safety plan optimizes the organization of your HACCP safety plan as well as your daily activity documentations. You never have to worry about any missing or misplaced documents when food safety auditors arrive. It helps business operators in the food industry identify the critical points for food safety. It also contains appropriate steps to ensure that these points are adequately controlled. As food businesses are different, it's really hard to find completely similar food entities and create a food safety plan template for all.
Food businesses are unique in terms of the production process, the category of food they order and use, the food they produce, the production volumes they have, the customers they serve, and much more. It's also impossible to create a HACCP plan template based on business activity because the nature of operations can be very different such as for shops and cafes.
All of these mentioned conditions and specialized processes affect the content of your HACCP plan and criteria for food safety. Potential hazards and their analysis that you need to consider as food safety risks will vary depending on these factors. To ensure the safety of your food products, use one of our HACCP plan templates to establish correct control measures, procedures for monitoring, and documentation procedures, plans, and schedules.
If you're serving your wholesome food in a buffet, you need to ensure that hot food is not sitting out for more than 2 hours. Monitoring the time and temperature during this period is an important part of critical control point CCP monitoring. When you're serving your dishes a la carte, this risk doesn't apply to you because your food products will not be held for 2 hours.
If you're cooking food, you need to measure the internal temperature of the food item and register the results to temperature monitoring charts. Cooking food at the right temperature and adequate time and using the correct processing methods and monitoring techniques will ensure that any harmful bacteria and other pathogens are killed. When the temperature is not high enough during thermal processing, the additional cooking time must be added to provide wholesome food.
As soon as you're dealing with products only at room temperature and you're not cooking them, this requirement doesn't apply to you because the risk is not present. When your business is ordering frozen and chilled food products, you need to check the products upon delivery whether they're at the right temperature.
Signs of improper transportation conditions tell you not to receive products that are not kept on an acceptable temperature level. Keeping a cold chain is critical and a well-known requirement to prevent any potential biological hazard and to provide safe food products.
If your business is ordering food at room temperature, this requirement doesn't apply to you and you have one daily monitoring less to worry about. Your concern shifts towards maintaining the quality of your product in clean conditions. These basic rules include following the correct ambient temperature , even if it's not one of the critical monitoring records. There are hundreds and thousands of conditions like these to keep in mind when composing and following your HACCP plan rules.
As you understand, it's impossible to create one right and compliant HACCP plan example that suits everyone in the food industry, even by the health inspectors. These digital HACCP document templates are easy to modify, download, and print and can fit your business' specialized processes.
Just click on the words you want to change, make any necessary modifications, and download your completed HACCP plan template for monitoring.
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