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In our previous blog post, we discussed key steps for starting a HACCP plan. We asked, “How do we develop a HACCP plan?†Here’s a quick recap of Part 1. First, we recommended understanding the seven HACCP principles. Second, based on our experience working with food processors, it's important to involve key managers from quality control, engineering, maintenance, and operations when developing the plan. Third, if your company produces multiple products, consider identifying all products that will be included in your HACCP plan. One reader even shared how reviewing each ingredient helped improve their control.
Now, where should you go next? The next critical steps in creating an effective HACCP plan involve honest and disciplined thinking about your entire production process—from the moment ingredients enter your facility to when your finished products are shipped out. As you review your process, ask your team these questions:
- Do we have detailed documentation of our processes?
- Where could potential hazards occur?
- Are there Critical Control Points (CCPs), and what controls should we put in place?
- Do we have enough documentation to train new employees and prepare for inspections?
These discussions can guide you toward a tailored HACCP plan that works for your business. You may also find the following steps helpful, based on experiences from other food companies.
**1. Map every step of your process.**
Even long-established businesses often benefit from a thorough, objective review of their processes. By visually mapping each step, you can uncover hidden food safety risks. Many successful food processors use a Process Workflow Chart to track each stage, from raw material entry to final packaging and shipping. This helps ensure no step is overlooked.
**2. Evaluate hazards and identify CCPs.**
According to the International HACCP Alliance, your plan should identify and prioritize hazards and their critical limits. A useful tool is the Decision Matrix, as suggested by the FDA. This matrix helps assess the likelihood of hazards at each process step and determines whether they qualify as CCPs.
**3. Use a Hazard Analysis Worksheet.**
Not every hazard is a CCP. If a control measure is already in place, the hazard may not require a CCP. CGMPs (Current Good Manufacturing Practices) are one such control that can help manage risks without labeling them as CCPs. We’ll explore this in more detail in future posts.
A Hazard Analysis Worksheet is a great way to evaluate each hazard. It includes areas like the step being reviewed, the type of hazard, its severity, and whether it's a CCP. This helps clarify why not all hazards need to be classified as CCPs.
**4. Maintain and update your HACCP plan regularly.**
Creating a plan is just the first step. Regular monitoring and updates are essential to keep your food safety efforts strong. Assigning a dedicated HACCP Coordinator can help you stay ahead of new risks. Whenever changes occur—like hiring new staff or switching suppliers—it’s wise to re-evaluate your plan.
For a deeper dive into the HACCP planning process, check out our HACCP Planning white paper.
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