HACCP Documentation

HACCP documentation will provide essential information and evidence that HACCP requirements have been satisfied and complied to. Individual documentation is recommended to ensure that each requirement is not missed. However, it can also be in a manual format but this is limited to mainly documentation and will not capture records. Effective HACCP documentation includes policy and objectives, related standard operating procedures, plans and programs and records of implementation.

Evidence of compliance to HACCP requirements includes the following (as minimum):

• HACCP team composition – they must be comprised of multi-disciplinary members. They must have knowledge and experience about food safety hazards and HACCP principles. HACCP team leader must be appointed and together with team members, must be equipped with relevant training.

• Product description – description of each product must be specified and clearly defined information such as product name and category; food safety characteristics; shelf-life; storage conditions; labelling requirement, allergen information etc.; method of production; transportation methods; preparation and/or handling; acceptance criteria or specifications.

• Intended and unintended use – define intended use based on expected use of the product. Consumer group of each product/process must be identified as well. They include target consumer groups, population (e.g., babies and children, pregnant, allergic or sick people etc.), further processing and potential alternative use of product. Consider any unintended but reasonably expected mishandling and misuse of end-product.

• Flow diagrams and its verification for accuracy – Flow diagram includes all steps in the operation where in a sequence of raw materials; intermediate products; end products; by-products and waste release; description of outsourced processes; and rework and recycling are detailed. Onsite verification of flow diagram must be done by the HACCP team to ensure all steps have been captured and nothing is missed.

• Hazard identification and analysis – identify biological, chemical and physical hazards that are reasonably expected to occur at each step in the flow diagram. Conduct hazard analysis through assessment of likelihood of occurrence of hazard and the severity of its adverse health effect. Determine appropriate control measure or combination of control measures for each significant food safety hazard in order to prevent, eliminate or reduce them to acceptable level.

• Determination of Critical Control Point (CCP) – this can be facilitated by the application of a decision tree as this is helpful for identifying whether the step in the flow diagram is a CCP for the identified hazard.

• Critical limits for each CCP – define appropriate and measurable critical limits such as time and temperature, pH, moisture etc.

• Monitoring and measuring of critical limits – this will ensure if critical limits are being met and CCP is in control. Monitoring must include methodology, frequency, devices to be used – its calibration details and responsibility.

• Corrective actions – if critical limit is not met, appropriate correction and corrective action shall be implemented along with the process to investigate the cause of the deviation.

• Verification activities and its evaluation – included here are PRPs and HACCP plan. This will confirm that implemented system meets the plan. For example: internal audit, 3rd party laboratory testing, review of monitoring records etc.

• Establishing the HACCP plan – this must contain information such as detail of CCP, hazard to be controlled, identified control measure(s), critical limit for each CCP, monitoring and measuring procedure, corrective actions, verification procedure, responsibilities and records.

• Validation – this ensures that the selected specific control measures are suitable to control hazards and produce a safe product. This shall be done prior to implementation of the HACCP plan and whenever there is change in the system.

• Internal audit – this will measure the effectiveness of the established HACCP system.

• Management review – this will determine continuing suitability, adequacy and effectiveness of the HACCP system.

• Prerequisite programs (PRPs) – as required to be verified, PRPs must be established, implemented and maintained to ensure food safety within the food establishment.