Benguet State University

College of Home Economics and Technology

Department of Human Nutrition

Hazzard Analysis Critical Control Points

(HACCP)
Topic

Binay-an, John Wayne Mines

Bulacan, Edmark Corpuz
Busoy, Jennifer Pad-eng
Dayap, Ronalyn Salming
Dongail, Juriz Balloging
Domocmat, Alexter Cayat
Magastino, Gemma Guzman
Sessi-it, Khezy Gel Bayawa
Bachelor of Science in Nutrition and Dietetics

Dafhney Marwy Joy O. Ligligan, RND

Faculty, Department of Human Nutrition
College of Home Economics and Technology

March 26, 2024

Foodservice System I
A. Hazard Analysis Critical Control Points (HACCP)
➢ It is a system which provides the framework for monitoring the total food
system, from harvesting to consumption, to reduce the risk of foodborne
illness. The system is designed to identify and control potential problems
before they occur.
➢ Since the mid-1980s, HACCP has been recognized as a best-practice means
of monitoring food safety in all segments of the food industry, including
foodservice operations.
➢ HACCP was first developed and used by the Pillsbury Company in the late
1950’s to provide safe food for America’s space program.
➢ In its Model Food Code, the Food and Drug Administration has recommended
the HACCP system “because it is a system of preventive controls that is the
most effective and efficient way to assure that food products are safe” (1999
FDA Model Food Code).
➢ The primary benefit of HACCP is that it emphasizes control of hazards
inherent to food at all stages of the processing continuum. Another advantage
is that it clearly identifies the food establishment as the final party responsible
for ensuring the safety of the food and handling procedures. HACCP is a
rational, scientific approach and monitors both current and past conditions
under which food is processed.
• Essential Features of HACCP
✓ Preventive system control.
✓ Identifies sensitive ingredients; pinpoints stages in processing that require
stricter control.
✓ Involves close monitoring of food materials.
✓ Looks into the hazards due to mishandling and improper storage.
• The Seven Steps in a HACCP System
1. Conduct a hazardous analysis
➢ The purpose of a hazardous analysis is to develop a list of hazards which are
likely to cause injury or illness if they are not controlled.
➢ Points to be considered in this analysis can include: skill level of
employees; transport of food; serving elderly, sick, very young children,
immune-compromised; volume cooling; thawing of potentially hazardous
 foods; high degree of food handling and contact; adequacy of preparation
and holding equipment available; storage, and method of preparation.
➢ The next step is to determine if the factors may influence the likely
occurrence and severity of the hazard being controlled. Finally, the hazards
associated with each step in the flow of food should be listed along with the
measures necessary to control the hazard.
2. Determine Critical Control Points (CCP’s)
➢ A critical control point (CPP) is any step in which hazards can be
prevented, eliminated or reduced to acceptable levels.
➢ CCP’s are usually practices/procedures which, when not done correctly, are
the leading causes of foodborne illness outbreaks. Examples of critical
control points include: cooking, cooling, re-heating, holding.
➢ To determine CCP’s ask the following questions:
• At this step in preparation can food become contaminated and/or can
contamination increase?
• Can this hazard be prevented through corrective action(s)?
• Can this hazard be prevented, eliminated or reduced by steps taken later
in the preparation process?
• Can you monitor the CCP?
• How will you measure the CCP?
• Can you document the CCP?
3. Establish Critical Limits
➢ A critical limit ensures that a biological, chemical or physical hazard is
controlled by a CCP. Each CCP should have at least one critical limit.
➢ Critical limits must be something that can be monitored by measurement or
observation. They must be scientifically and/or regulatory based. Examples
include: temperature, time, pH, water activity or available chlorine.
4. Establish Monitoring Procedures
➢ Monitoring is a plan which includes observations or measurements to assess
whether the CCP is being met. It provides a record of the “flow of food”
through the establishment. If monitoring indicates that the critical limits are
not being met, then an action must be taken to bring the process back into
control.
 ➢ The monitoring system should be easy to use and meet the needs of the food
establishment, as well as the regulatory authority. It is important that the job
of monitoring be assigned to a specific individual and they be trained on the
monitoring technique.
5. Establish Corrective Actions
➢ If the criteria for a CCP is not being met, some type of corrective action must
be taken. They must meet the standards established in Step 3, must be
based on facts for normal working conditions and be measurable.
➢ Corrective actions may range, for example, from “continue cooking until the
established temperature is reached” to “throw out the product,” depending on
the severity of the situation.
➢ HACCP plans should include the following: Who is responsible for
implementing the corrective action and what corrective action was taken?
They should be established in advance as part of the HACCP plan.
6. Establish verification procedures
➢ These procedures are activities, other than monitoring, that determine the
validity of the HACCP plan and that the system is operating according to the
plan.
➢ An important aspect of verification is to determine if the plan is scientifically
and technically sound. Also, that all the hazards have been identified and
that, if the HACCP plan is properly implemented, these hazards can be
effectively controlled.
➢ Verification can be accomplished by expert advice and scientific studies and
observations of the flow of food, measurements and evaluations. Another
means of verification is an on-site review of the established critical limits.
Each CCP will have one independent authority. This verification step
provides an opportunity to make modifications to the plan if necessary.
7. Establish record-keeping and documentation procedures
➢ Record-keeping and documentation procedures should be simple to
complete and include information that illustrates that the established
standards are being met. Employees need to be trained on the record-
keeping procedures and why it is a critical part of their job. Examples of
records include time/temperature logs, checklists, forms, flowcharts,
employee training records, and SOP’s.
• Identification of the Critical Control Points (CCPS) Required to Control the
Identification Hazards

✓ In general, CCP determination involves identifying and characterizing the

hazards, the control measures, and the processing steps where control is
applied. Thus, it is imperative that the HACCP team revisit and re-evaluate the
Hazard Analysis as well as the Flow Diagram.
✓ If a significant hazard that is reasonably likely to occur is identified in the
Hazard Analysis, it must be controlled somewhere in the food processing and
handling system.
✓ Due to the rigorous HACCP requirements for setting appropriate CLs and
monitoring, there are certain hazards in certain situations which are more
appropriately controlled by prerequisite programs. This has been the subject of
some debate and has led to two approaches in dealing with such hazards.
While they differ philosophically, the end result of these two approaches is
similar.
• Approach A: This approach is used by some HACCP auditors in the regulatory
and private sector. It dictates that a hazard deemed significant in the Hazard
Analysis must be controlled at a CCP. It then follows that a hazard which is, in
fact, managed by a prerequisite program is considered not "reasonably likely to
occur" because of the prerequisite program.
• Approach B: In this approach, prevention and control of identified significant
hazards can either be at a CCP or through rigorously applied prerequisite
programs.
✓ No set number of CCPs is required in HACCP. Rather, CCPs must be
determined for each specific food processing and handling system and be
appropriate to that specific system. Having too many CCPs could
unnecessarily encumber and burden the implementation of the HACCP plan.
Conversely, having too few CCPs could jeopardize food safety.
✓ CCPs that involve subjective control measures (e.g., visual parameters,
observations) rather than objective control measures (e.g., temperature, time)
are difficult to implement and require more creativity with regard to CLs and
monitoring procedures. For this reason, many HACCP plans now have fewer
 CCPs than they did historically, with the emphasis instead being placed on
sound, well-conceived, and well-implemented Prerequisite Programs.
A) CCP DECISION TREE
✓ In a traditional HACCP application, the original or modified version of the NACMCF
CCP decision tree or flow chart is used. Applying this decision tree involves asking a
series of questions to determine whether a process step is a CCP. An example of a
modified CCP decision tree is shown in Figure 1.

B. CCP DETERMINATION
✓ An alternative procedure for CCP determination is to incorporate appropriate
questions from the decision tree onto a form, as shown in Table 1. This format may
be a little more useable and engaging for HACCP team members than the tree
format. Each step from the flow diagram is listed in the first column and significant
hazards from the hazard analysis are listed in the second column. The HACCP team
 responds to the questions listed in subsequent columns and ultimately identifies the
CCP in the last column.

• Establishment of the Critical Limits that Must be Met at Each Identified CCP
✓ A critical limit is a maximum and/or minimum value to which a biological, chemical
or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to
an acceptable level the occurrence of a food safety hazard.
✓ 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.
✓ Critical limits may be based upon factors such as: temperature, time, physical
dimensions, humidity, moisture level, water activity (aw), 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. An
example of a criterion is a specific lethality of a cooking process such as a 5D
reduction in Salmonella. The critical limits and criteria for food safety may be derived
from sources such as regulatory standards and guidelines, literature surveys,
experimental results, and experts.
✓ The establishment of critical limits involves determining precise parameters that must
be upheld at each Critical Control Point (CCP) in a food safety plan. These limits are
essential for effectively controlling hazards and ensuring the safety of the food
supply chain. At each identified CCP, specific criteria are set to mitigate potential
risks to food safety. These criteria serve as checkpoints to verify that the food
production process is operating within safe parameters.

• Establishment of Procedures to Monitor CCPS

✓ Establishing HACCP monitoring procedures isn’t a standard process. While this
methodology makes it simpler to set up a monitoring system, organizations must
tweak the procedures to their specific needs and preferences. So, don’t be afraid
to make adjustments as you go, especially when setting up these monitoring
procedures for the first time.
✓ Monitoring is the act of conducting a planned sequence of observations or
measurements of control parameters to assess whether a CCP is under control.
✓ A monitoring system for each CCP is required to demonstrate that it operates
within a specified critical limit, which significantly reduces the risk of unsafe
product reaching the consumer.

✓ Some Basic Steps in the HACCP Monitoring Process:

1) Determine The Critical Limits
➢ The first step in setting up your monitoring procedure is setting your critical
limits for your control points. Again, the control points are areas in the
production process where you can spot, analyze, and correct issues right
away. The critical limits are the boundaries that must not be exceeded to
prevent or eliminate hazards. This could be the internal temperature for
cooking food and eliminating bacteria, storage conditions, and more.
2) Choose the Right Monitoring Methods
➢ The right monitoring methods for your organization largely depend on the
products you’re producing and the way you manufacture them. Some
organizations require temperature and humidity monitoring, some require pH
level monitoring, while others must monitor very specific parameters that are
unique to their industry.
 ➢ Either way, it’s critical to keep track of all the parameters relevant to the
safety and quality of your products.
3) Set the Monitoring Frequency
➢ The next step is establishing how frequently the CCPs in your workflow are
monitored. To determine this, you need to consider the stability of the
process, the likelihood of risks, and the regulatory requirements you must
follow. From there, it will be much easier to establish the monitoring
frequency of your HACCP procedures.
4) Document the Processes
➢ Like every process, HACCP monitoring requires documentation. It’s critical
for modern organizations to remain transparent. That way, it’s easier to share
information and find potential causes of problems.
➢ So, when monitoring facilities and processes using HACCP, make sure that
the team documents everything they do so that the team can revisit the data
whenever necessary.
5) Regularly Review and Update the Procedures
➢ After running the HACCP monitoring methods, the next step is reviewing the
process. Like any process, HACCP monitoring requires continuous
improvement and adjustment. That’s why you must review how well the
monitoring procedures worked and whether they were able to prevent or
minimize risks.

• Establishment of Corrective Actions to be Taken When there is a Deviation

Identified by Monitoring a Given CCP
➢ Corrective action is taken when monitoring at a CCP shows a deviation at a
critical limit. This intervention is important because it prevents a potentially
unsafe product reaching the final consumer. Codex defines a corrective
action “as any action to be taken when the results of monitoring at the CCP
indicate a loss of control”. The range of potential deviations means more than
one corrective action may be necessary for each CCP.
➢ There are two different types of corrective action:
a. Actions taken to prevent loss of control at a CCP. This occurs when
monitoring shows a trend towards a loss of control. Process adjustments
 should be made to bring the process within operating limits to prevent a
deviation, followed by an investigation into why they were not achieved.
b. Actions to be taken following a deviation at a CCP. This requires actions to
regain control over the process, identify and control the affected product,
followed by an investigation into the loss of control.

➢ Process Adjustments
− Corrective action to prevent or following a deviation at a CCP may require
adjustments to the process. A provisional solution to regain control may be
put in place while a permanent one is evaluated. This adjustment may not
be possible and may involve stopping the line until the problem has be
assessed and corrected. Temporary adjustments or permanent
modifications to the process must not cause or increase the risk of a
hazard.
➢ Managing Affected Product
− Procedures must be in place to identify, quarantine and assess non-
conforming product when a critical limit is exceeded. Affected product must
be clearly marked (e.g., reason for hold) and if required held under
conditions to minimize further deterioration. The assessment of a non-
conforming product must be based on expert evaluation and where
appropriate further chemical, physical or microbiological tests. Satisfactory
sampling and tests may determine the product is safe to release. Unsafe
products can be reworked/reprocessed to make them safe or disposed if
this is not possible.

✓ Corrective Action Plan

➢ Predefined corrective actions must be documented and communicated to all
relevant personnel. This document would usually outline the following:

o immediate and short-term actions take to regain control over the

process and deal with any affected product
o define responsibilities for implementing and overseeing corrective
actions and who needs to be informed when a deviation occurs
 o explain how to investigate and determine the cause for the loss of
control
o verification activities to determine the effectiveness of the corrective
action taken2
o information that must be recorded following a corrective action

✓ Corrective Action Records

➢ Adequate records must demonstrate appropriate actions were taken to
prevent an unsafe product reaching the consumer and a reoccurrence of a
similar incident. The following information should be recorded:
o what actions were taken to regain control over the process and by
whom
o product code and quantity of affected product
o disposition of affected (e.g., rework or disposal)
o cause of the deviation and action taken to prevent a recurrence
o review of effectiveness of corrective action
➢ All records must be dated and signed by those responsible for the corrective
action.

• Establishment of Procedures to Verify that HACCP System is Working

1. The Person in Charge should, among other actions, spot check
temperatures of products in the refrigerators: check invoices for
temperatures of food on delivery and check temperatures of food on serving
line and being removed from cooking.
2. The Person in Charge should watch to see if employees are washing their
hands, cleaning and sanitizing equipment, and taking other steps to limit
cross contamination
3. Verification procedures may include:
a. Establishment of appropriate verification inspection schedules.
b. Review of the HACCP plan.
c. Review of the CCP records.
d. Review of the deviations and dispositions.
e. Visual inspection of operations to observe whether CCPs are under
control.
 f. Random sample collection and analysis.
g. Review of critical limits to verify that they are adequate to control
hazards.
h. Review of written record of verification inspections covering
compliance, deviations, or corrective actions taken.
i. Review of modifications of the HACCP plan.
4. Determine if the food service personnel understand and are following the
HACCP system for the facility.
5. Concentrate on the critical offenses associated with incidence of food borne
illness, including time temperature control and prevention of cross
contamination.
6. Begin a HACCP based sanitation inspection with the menu.

• Establishment Of Effective Record Keeping Systems That Document the

HACCP Plan
➢ Establishing effective record-keeping systems is crucial for documenting an
HACCP (Hazard Analysis and Critical Control Points) plan. Here's a
structured approach to achieve this:
Identify Required Records: Determine which records are necessary to
document the HACCP plan. These typically include:
➢ Hazard analysis: -Records should include a thorough analysis of potential
hazards associated with each step of the food production process.
− Identify biological, chemical, and physical hazards.
− Document the likelihood and severity of each hazard.
− Outline control measures to mitigate or eliminate hazards.
− Include information on the source of hazards and how they are
controlled.
➢ CCP monitoring records:
• Document monitoring activities at Critical Control Points (CCPs) where
control measures are applied.
• Record observations, measurements, or tests conducted to ensure CCPs
are under control.
• Note the frequency of monitoring and responsible personnel.
 • Include details on equipment used for monitoring and any deviations from
critical limits.
➢ Critical limits for each CCP:
• Specify the critical limits that must be met to ensure control of hazards at
each CCP.
• Include numerical values, temperature ranges, time limits, pH levels, etc.
• Critical limits should be based on scientific data, regulatory requirements,
or industry standards.
➢ Corrective actions taken:
• Document any deviations from critical limits or failures in control measures.
• Outline corrective actions taken to bring the process back under control.
• Include the cause of the deviation, who took corrective action, and any
follow-up measures
➢ Verification procedures:
• Record activities conducted to verify the effectiveness of the HACCP plan.
• Include internal audits, reviews of records, and evaluations of monitoring
procedures.
• Document who conducted the verification, when it was conducted, and any
findings or observations.
➢ Validation activities:
• Document the scientific evidence or rationale used to validate the HACCP
plan.
• Include studies, experiments, or data that support the control measures
implemented.
• Record validation activities conducted during the development or
modification of the HACCP plan.
➢ Supplier information:
• Maintain records of suppliers providing raw materials, ingredients, or
packaging materials.
• Include contact information, product specifications, and certificates of
analysis.
• Document any assessments or audits conducted to evaluate supplier
performance.
➢ Training records:
• Keep records of employee training related to food safety and HACCP
principles.
• Document training sessions attended, topics covered, and assessment
results.
• Include information on trainers, training materials used, and dates of
training.
➢ Maintenance logs for equipment
• Record maintenance activities for equipment used in food production.
• Include preventive maintenance schedules, repairs performed, and parts
replaced.
• Document equipment calibration checks and any adjustments made.
➢ Receiving and shipping records:
• Maintain records of incoming and outgoing shipments of raw materials,
finished products, and packaging materials.
• Include information on suppliers, quantities received or shipped, dates,
and batch/lot numbers.
• Record inspection results, including any deviations or rejections.
➢ Calibration records for measuring devices:
• Document calibration activities for measuring devices used in monitoring
critical control points.
• Include calibration schedules, calibration methods used, and calibration
results.
• Record adjustments made during calibration and any deviations from
calibration standards.

Design Record Forms: Create standardized forms for recording relevant

information. These forms should be clear, easy to understand, and leave
enough space for necessary details. Electronic forms or software systems
may also be used for this purpose.
Establish Procedures: Develop clear procedures for completing and
maintaining records. Ensure that personnel responsible for record-keeping
understand their roles and responsibilities.
 Train Personnel: Provide training to employees on how to properly complete
records. This training should cover the importance of accurate record-
keeping, how to accurately record data, and the consequences of incomplete
or inaccurate records.
Implement Verification Measures: Put in place systems to verify that
records are being completed accurately and in a timely manner. This may
include regular audits or reviews by designated personnel.
Utilize Technology: Consider utilizing technology to streamline record-
keeping processes. Electronic systems can automate data collection, reduce
errors, and provide easier access to records for analysis and review.
Maintain Records Securely: Establish protocols for storing records securely
to prevent loss, damage, or unauthorized access. This may include password
protection for electronic records and secure storage facilities for physical
documents.
Regularly Review Records: Schedule regular reviews of records to ensure
compliance with the HACCP plan and regulatory requirements. This will help
identify any trends or issues that need to be addressed.
Document Changes: If any changes are made to the HACCP plan, ensure
that corresponding changes are made to record-keeping procedures and
forms. Document these changes and provide appropriate training to affected
personnel.
Continuous Improvement: Continuously evaluate the effectiveness of the
record-keeping system and look for opportunities to improve efficiency and
accuracy. Solicit feedback from employees involved in the process and make
adjustments as needed.

Examples of HACCP Records

A. Ingredients for which critical limits have been established.
1. Supplier certification records documenting compliance of an ingredient
with a critical limit.
2. Processor audit records verifying supplier compliance.
3. Storage records (e.g., time, temperature) for when ingredient storage is a
CCP.
B. Processing, storage and distribution records
 1. Information that establishes the efficacy of a CCP to maintain product
safety.
2. Data establishing the safe shelf life of the product; if age of product can
affect safety.
3. Records indicating compliance with critical limits when packaging
materials, labeling or sealing specifications are necessary for food safety.
4. Monitoring records.
5. Verification records.
C. Deviation and corrective action records.
D. Employee training records that are pertinent to CCPs and the HACCP plan.
E. Documentation of the adequacy of the HACCP plan from a knowledgeable
HACCP expert.

Example of a HACCP plan summary table

• HACCP Flow Diagram

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