There are seven principles of HACCP that need to be used and implemented in any food industry throughout the world. These principles include the following:

Hazard Analysis

This process includes recognising any hazards to food safety in a particular manufacturing program. A plan should be put into place to prevent any danger from those hazards, which could include biological or chemical contamination.

Critical Control Points

The second principle is to recognise critical control points. These would be points in the manufacturing of the food that could pose the most risk. All hazards must be found and managed during this process.

Critical Limits

Control points will need critical limits. These limits, which include both minimums and maximums, must be followed. Any breaks in limits will need to be addressed and handled.

Critical Control Monitoring

This monitoring standard is set into place to ensure all critical control points are noted and watched for any changes that could lead to risk. Critical limits will also be monitored during this principle.

Corrective Action

There should be a plan for specific corrective actions should a hazard arise at a critical control point. This could include a critical limit minimum not being met, or alternatively, a critical limit maximum being overtaken. Corrective actions should be used immediately to avoid any injury or illness to humans from the hazard.

Procedures

A set of procedures should be set forth in order to ensure HACCP is always followed and implemented correctly in the food manufacturing workplace. All employees involved in the process should be able to verify the steps for which they are responsible.

Record Keeping

Any food manufacturing or packaging facility should keep verifiable and accurate records. This should include details of their own HACCP plan as well as their own established critical control points and critical limits. If corrective action has to be taken, then this should be documented as well.

There are twelve steps to help ensure the successful implementation and integration of HACCP throughout a company:

1. Assemble a HACCP team with the appropriate product-specific knowledge and expertise to develop an effective Food Safety Plan. The team should comprise individuals familiar with all aspects of the production process, plus specialists with expertise in specific areas, such as engineering or microbiology. It may be necessary to use external sources of expertise in some cases.
2. Describe the product in full detail, including composition, physical/chemical structure, microcidal/static treatments, packaging, storage conditions, and distribution methods.
3. Identify the intended/expected use of the product by the end user. It is also important to identify the consumer target groups. Vulnerable groups, such as children or the elderly, may need to be considered specifically.
4. Construct a flow diagram that provides an accurate representation of each step in the manufacturing process—from raw materials to end product—and may include details of the factory and equipment layout, ingredient specifications, features of equipment design, time/temperature data, cleaning and hygiene procedures, and storage conditions.
5. Perform an onsite confirmation of the flow diagram to confirm that it is aligned with actual operations. The operation should be observed at each stage and any discrepancies between the diagram and normal practice should be recorded and amended. It is essential that the flow diagram is accurate, since the hazard analysis and identification of Critical Control Points (CCPs) rely on the data it contains.
6. Conduct a hazard analysis for each process step to identify any biological, chemical, or physical hazards. This assessment also includes rating the hazard using a risk matrix, determining if the hazard is likely to occur, and identifying the preventive controls for the process step.
7. Determine Critical Control Points (CCPs)—those areas where previously identified hazards may be eliminated. The final HACCP Plan will focus on the control and monitoring of the process at these points.
8. Establish critical limits and develop processes that limit risk at CCPs. More than one critical limit may be defined for a single step. Criteria used to set critical limits must be measurable and include rating and ranking of hazards for each step of the flow chart.
9. Monitor CCPs and develop processes for ensuring that critical limits are followed. Monitoring procedures must be able to detect loss of control at the CCP and should provide this information in time to make appropriate adjustments so that control of the process is regained before critical limits are exceeded. Where possible, process adjustments should be made when monitoring results indicate a trend towards a loss of control at a CCP.
10. Establish preplanned corrective actions to be taken for each CCP in the HACCP plan that can then be applied when the CCP is not under control. If monitoring indicates a deviation from the critical limits for a CCP, action (e.g., proper isolation and disposition of affected product) must be taken that will bring it back under control.
11. Establish procedures for verification to determine whether the HACCP system is working correctly. Verification procedures should include detailed reviews of all aspects of the HACCP system and its records. The documentation should confirm that CCPs are under control and should also indicate the nature and extent of any deviations from the critical limits and the corrective actions taken in each case.
12. Establish proper documentation and recordkeeping for all HACCP processes to ensure that the business can verify that controls are in place and are being properly maintained.

The production of safe food products requires that the HACCP system be built upon a solid foundation of prerequisite programs. Each segment of the food industry must provide the conditions necessary to protect food while it is under their control. This has traditionally been accomplished through the application of cGMPs. These conditions and practices are now considered to be prerequisite to the development and implementation of effective HACCP plans. Prerequisite programs provide the basic environmental and operating conditions that are necessary for the production of safe, wholesome food. Common prerequisite programs may include, but are not limited to:

Facilities.

The establishment should be located, constructed and maintained according to sanitary design principles. There should be linear product flow and traffic control to minimize cross-contamination from raw to cooked materials.

Supplier Control.

Each facility should assure that its suppliers have in place effective GMP and food safety programs. These may be the subject of continuing supplier guarantee and supplier HACCP system verification.

Specifications.

There should be written specifications for all ingredients, products, and packaging materials.

Production Equipment.

All equipment should be constructed and installed according to sanitary design principles. Preventive maintenance and calibration schedules should be established and documented.

Cleaning and Sanitation.

All procedures for cleaning and sanitation of the equipment and the facility should be written and followed. A master sanitation schedule should be in place.

Personal Hygiene.

All employees and other persons who enter the manufacturing plant should follow the requirements for personal hygiene.

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