Hazard Analysis and Critical Control Point (HACCP) is a globally recognized food safety management method. It provides a systematic, preventive approach to identifying and preventing potential hazards in the food production and processing industry. The system assures both customers and regulatory bodies that a food safety program is well-managed.
The National Advisory Committee on Microbiological Criteria for Foods (NACMCF) and the Food and Drug Administration (FDA) define HACCP as "a management system in which food safety is addressed through the analysis and control of biological, chemical, and physical hazards from raw material production, procurement, and handling, to manufacturing, distribution, and consumption of the finished product."
Origin and Adoption HACCP was first developed in the 1960s by scientists and engineers with the goal of ensuring food safety for astronauts. Over time, various international organizations and regulatory agencies adopted and recognized this system.
In the United States, federal and state regulatory agencies have widely adopted the HACCP approach to safeguard public health. Since January 1998, all seafood processors that transport their products across state lines have been required to implement HACCP plans. In the same year, the United States Department of Agriculture (USDA) also began mandating HACCP plans for meat and poultry processing plants. Many state and local food regulatory agencies base their inspections on HACCP principles and may require such plans for specific food items. HACCP has also become a foundational element for food safety education programs.
HACCP is a mandatory requirement in many countries for food establishments involved in producing, handling, and distributing food products. It is particularly vital for businesses that deal with high-risk products like meat, dairy, seafood, and processed foods. Beyond food, HACCP is increasingly being applied in the cosmetics and pharmaceutical manufacturing industries.
HACCP principles can also help your company align with Hazard Analysis and Risk-based Preventive Controls (HARPC) rules, which are part of the FDA’s Food Safety Modernization Act (FSMA). While implementing a HACCP system provides an excellent basis for establishing your FSMA compliance system, it does not automatically ensure full FSMA compliance. Additionally, prerequisite programs such as current Good Manufacturing Practices (cGMPs) are an essential foundation for developing and implementing successful HACCP plans
Successful HACCP implementation requires a few key procedures, policies, and programs, including important preventive measures:
HACCP is an international standard (ISO 22000) that requires adherence to the following seven principles:
This principle involves identifying process steps where biological, chemical, or physical hazards might occur. You need to analyze all processes for these risks, determining ways to mitigate or eliminate their probability. The entire production process should be documented, including justification for any hazards you've excluded.
CCPs are specific points in the manufacturing process where significant hazards can be controlled, minimized, or prevented. A single CCP might help control multiple hazards, or you might need to apply controls at more than one CCP to manage a single hazard.
A critical limit is a specific value (e.g., temperature, pH, time, weight). When this limit is met, the hazard is considered eliminated, prevented, or reduced to an acceptable level. Your food safety management system must establish critical limits for all CCPs.
This principle requires a team member to measure the effectiveness of the applied control at the CCP. When setting up the monitoring process, record the measurement method, its frequency, and the responsible team member. This might involve using a thermometer or more specialized equipment.
If monitoring reveals a breach of a critical limit at a CCP, you must take immediate action to avert the hazard. The HACCP team should also work to prevent future breaches. This principle emphasizes proactive maintenance planning, preferring preventive or predictive approaches over reactive ones.
Auditing the effectiveness of controls at the CCP is crucial for the success of your HACCP approach. This includes verifying that controls work as intended, reviewing HACCP records, testing products, and calibrating equipment as needed. A Computerized Maintenance Management System (CMMS) can automate verification activities and checks (like preventive SOPs) and save these checks in the cloud for inspections and audits.
Your recordkeeping in HACCP is vital for creating an audit trail for regulators and as a resource for improving the HACCP program. Document all details of your HACCP program, including responsible team members, flow diagrams, product descriptions, critical limits, monitoring procedures, and preventive, predictive, and corrective plans. Centralized records, visible to all stakeholders, are recommended. A CMMS, like MaintainX, serves as an excellent real-time recordkeeping tool, allowing you to record measurements and collaborate with other teams.
HACCP Certification To obtain a HACCP certificate, businesses follow a series of steps, which include conducting hazard analysis, determining CCPs, establishing critical limits, developing monitoring procedures, establishing corrective actions, implementing verification procedures, maintaining records, and training staff. The final step involves engaging an accredited certification body to conduct an independent audit and verify compliance.
HACCP certificates do not have a standardized expiration date. Their validity can vary depending on industry regulations, specific certification bodies, and requirements. While HACCP training certificates generally do not expire, some certification bodies or industries may require regular refresher courses or continuing education to ensure ongoing knowledge and skills for effective HACCP implementation.
While all these systems relate to food safety, they have distinct focuses:
HACCP and Maintenance Management A strong link exists between HACCP principles and effective maintenance management. Implementing a preventive maintenance program ensures equipment functions as expected, directly supporting critical limits and reducing hazards. When the monitoring process reveals a breach of a critical limit, having proactive maintenance plans (like preventive or predictive maintenance) in place allows you to take action before a major issue arises. This proactive approach ensures you are checking and pre-empting any breaches.
Furthermore, a Computerized Maintenance Management System (CMMS) is highly recommended for HACCP implementation. A CMMS can automate verification activities and checks (such as preventive SOPs), and save these verification checks in the cloud for easy access during inspections and audits. It also serves as an excellent real-time recordkeeping tool, allowing you to record measurements and collaborate with other teams. For example, if a measurement breaches a critical limit, you can quickly request assistance from the maintenance team to resolve the problem caused by a machine. The monitoring system set up on a CMMS can also assist with internal audits, helping you maintain standards higher than regulatory requirements. When regulators come for inspections, a CMMS allows you to quickly extract critical information in seconds.
