Implementation of HACCP is driven by the commitment and involvement of management and personnel in accordance with the requirements, through the establishment of a HACCP team, defining the scope, describing product details, stating objectives, preparing a process flow diagram, conducting an on-site verification, identifying all potential hazards, including training, establishing documentation procedures, validating the plan, and implementing monitoring measures at each CCP, as well as determining critical limits.
1. Establishing the HACCP Team and Defining the Scope
The team should consist of personnel from various departments with different functional responsibilities and relevant expertise. Typically, the team comprises 9–11 members and includes representatives from production, quality control, maintenance, sanitation, and disinfection.
2. Describing Product Details Including Safety Information such as:
Ingredients
Physical/chemical characteristics (e.g., aw, pH, allergens)
Processing methods/technologies (e.g., heating, freezing, smoking)
Packaging materials
Shelf life/durability
Storage conditions
Distribution method
Relevant regulations should be considered in the HACCP plan development, such as limits on food additives and microbial counts. Products with similar characteristics or processing steps may be grouped.
3. Identifying Product Intended Use and Target Consumers
State the intended use and users of the product. Anticipated use can be informed by external sources (e.g., government or research organizations). If food is made for vulnerable populations, control measures may require enhancements (e.g., more frequent monitoring). Validation through product testing or other activities may be necessary to ensure food safety.
4. Developing the Process Flow Diagram
Should cover all production steps including rework
Identify all inputs
For complex operations, use sub-process flow diagrams and show interconnections
Use the diagram to analyze hazards and assess likelihood (increase, decrease, or initiate)
The diagram must be accurate, detailed, and clearly depict step sequence and interrelations including raw material receipt, additives, utilities, intermediate products, outsourced processes, rework, recycling, final products, by-products, and waste removal
5. On-Site Verification of Process Flow Diagram
Verify every step of actual production on-site and compare with the diagram. Make corrections if needed. This can be done by one or more individuals with sufficient process knowledge.
6. Identifying and Analyzing Hazards to Determine Significant Hazards and Control Measures
All potential hazards must be identified at each step. Their significance must be assessed based on:
The type of food
The likelihood of hazard occurrence with only PRP in place
Severity of health impact
Equipment/facility design
Microbial survival or growth
Persistence of toxins/chemicals/physical hazards
Intended use and consumer mishandling likelihood
Acceptable hazard levels
7. Determining Critical Control Points (CCPs)
CCPs are control steps where hazards are reduced to acceptable levels. More than one CCP may exist for a single hazard. Decision trees or other methods can be used, focusing only on significant hazards.
8. Establishing Critical Limits for Each CCP
Critical limits define whether a CCP is under control and help distinguish between acceptable and unacceptable products. Limits must be measurable or observable. Multiple criteria (e.g., time, temperature, moisture, pH, aw, chlorine) may be used. Validation may involve scientific studies, regulations, third-party testing, or equipment manufacturer data, as explained in CXG 69-2008 Guidelines for the Validation of Food Safety Control Measures.
9. Establishing a Monitoring System for Each CCP
Must enable timely detection of loss of control and implementation of corrective actions
Should be continuous or have a frequency sufficient to ensure CCP control
Use physical or chemical tests (microbiological testing is less suitable)
Performed by qualified personnel with authority to take corrective actions
10. Establishing Corrective Actions
Corrective actions must address control loss at each CCP. If deviations occur, affected products are deemed potentially unsafe. Actions may include restoring control, segregating affected product, and assessing product safety (with expert input if needed). Products may be reprocessed, used for other purposes, or destroyed. Root cause analysis should be performed to prevent recurrence. Actions and outcomes must be documented and periodically reviewed for effectiveness.
11. Validation and Verification of the HACCP Plan and Operational Procedures
11.1 Validation
Ensure that the HACCP plan components (hazard identification, CCPs, critical limits, control measures, monitoring and verification frequency, and record types) effectively control significant hazards. Expert-determined limits must be applicable to the specific process/product. Validation is required at initial implementation and after any changes.
11.2 Verification Procedures
Verification activities may include:
Observations
Internal/external audits
Calibration
Sampling and record review
These ensure the HACCP system is being implemented as designed.
12. Documentation and Record-Keeping
HACCP procedures must be documented, and records must be maintained appropriately. Examples include:
HACCP team composition
Hazard analysis with scientific support
CCP decision rationale
Critical limit justification
Validation records
Plan modifications
Verification should be frequent enough to confirm effectiveness. The review must ensure all hazards are correctly identified, controls are adequate, and deviations and corrective actions are handled appropriately.
Examples of records:
CCP monitoring logs
Deviation and corrective action logs
Verification activity records
Electronic data storage
13. Training
Develop SOPs and define CCP responsibilities.
Training programs must suit staff knowledge and skill levels
Programs should be reviewed and updated as necessary
Retraining may be needed, especially when corrective actions are involved
