Twelve Steps for Developing a HACCP System

Step 1. Assemble the HACCP team

The team needs product and process knowledge appropriate to the operation. A multidisciplinary team is preferable; obtain external expertise if it is unavailable internally. Define the scope, including relevant parts of the food chain and the hazard types to be considered.

Step 2. Describe the product

Prepare a complete description of relevant food safety characteristics: composition, physical and chemical properties, treatments such as heating, freezing, salting or smoking, packaging, shelf life, storage conditions and distribution methods.

Step 3. Identify intended use

Consider the use expected by customers and final consumers. Where relevant, consider vulnerable groups and reasonably foreseeable use.

Step 4. Construct the process flow diagram

The HACCP team should map all process steps. When examining a specific operation, consider the preceding and subsequent steps as well.

Step 5. Confirm the flow diagram on site

Check the diagram against actual operations across relevant stages and operating periods, and revise it to reflect practice.

Step 6. Conduct hazard analysis

List potential hazards at each step, analyse their significance and consider suitable control measures.

Consider hazards reasonably likely to occur from primary production through processing, manufacturing, distribution and consumption.

Determine which hazards must be prevented, eliminated or reduced to acceptable levels to produce safe food.

Step 7. Determine critical control points

More than one control step may address the same hazard. A decision tree can support CCP determination, but it must be applied with understanding of the operation, whether production, slaughter, processing, storage or distribution. A single tree does not fit every situation; other justified methods may be used. Train the team in the chosen approach.

If a significant hazard requires control and no suitable measure exists at that or another step, modify the product or process to introduce an effective control measure at an appropriate stage.

Step 8. Establish validated critical limits

Specify and validate critical limits for each CCP. More than one limit may be needed. Examples include temperature, time, moisture, pH, water activity and available chlorine, or a validated observable criterion where appropriate. Limits must be justified for the product and process.

Step 9. Establish monitoring for each CCP

Monitoring uses planned observations or measurements against critical limits. It must detect loss of control and provide information soon enough to make appropriate adjustments.

Where possible, respond to trends before a limit is exceeded. A designated person with the necessary knowledge and authority should evaluate monitoring data and initiate action.

When monitoring is not continuous, the frequency must be sufficient to provide confidence that the CCP remains under control. Many in-process checks must be rapid because lengthy laboratory analysis cannot provide timely control information.

Physical or chemical measurements can often provide faster control information than microbiological tests when they are valid indicators of the hazard control. Monitoring records should identify the person performing the check and the responsible reviewer.

Step 10. Establish corrective actions

Define actions for each CCP to address deviations when they occur.

Actions must restore control and include identification, segregation where appropriate, evaluation and disposition of potentially affected product. Record deviations and product decisions in the HACCP records.

Step 11. Validate the plan and establish verification procedures

Validate the plan’s capability to control the relevant hazards. Establish verification activities to check correct implementation and ongoing effectiveness. Methods may include record review, observation, audits, sampling and testing; frequency should be sufficient for the operation. Examples include:

• Reviewing the HACCP system and records.
• Reviewing deviations, corrective actions and the disposition of affected products.
• Confirming that CCPs are controlled.
• Evaluating the effectiveness of the elements of the HACCP plan.

Step 12. Establish documentation and records

Documentation and records support implementation, maintenance and continual improvement of the system.

Codex CXC 1-1969