A HACCP plan checklist is a useful tool for assessing and reviewing a HACCP plan. It includes questions to help identify potential hazards, assess the effectiveness of HACCP controls and plan updates and document plan reviews. It is essential for ensuring that food safety standards are met.
An effective, accurate HACCP Plan must be in place. The HACCP plan must be developed using Codex Alimentarius HACCP principles with reference to relevant legislation, Tesco COP and industry guidance.
The HACCP plan must include a detailed scope
1.2 - HACCP TEAM
The HACCP system must be developed by a multi-disciplinary team which must have product specific knowledge and expertise
The team includes members from at least the following disciplines (not exhaustive list): Technical, Production, Engineering.
Support from NPD, purchasing, distribution etc as appropriate.
At least one member of the team has completed a recognised qualification in advanced HACCP (aspirational)
Refresher training of the HACCP team is undertaken annually, regardless of any change in Production processes (aspirational)
1.3 - PRE-REQUISITE PROGRAMMES
All environmental and operational controls that are necessary to produce of safe and legal food products must be in place. These cover good manufacturing practises throughout the site. They may include... (Not an exhaustive list)
Personal hygiene - control measures and monitoring procedures for PRP must be clearly identified and documented
Staff training - control measures and monitoring procedures for PRP must be clearly identified and documented
Pest Control - control measures and monitoring procedures for PRP must be clearly identified and documented
Cleaning procedures - control measures and monitoring procedures for PRP must be clearly identified and documented
Glass / hard plastic control - control measures and monitoring procedures for PRP must be clearly identified and documented
Waste control - control measures and monitoring procedures for PRP must be clearly identified and documented
Maintenance procedures - control measures and monitoring procedures for PRP must be clearly identified and documented
1.4 - PRODUCT
A full description of the product must be documented including relevant safety information...
Product composition
Origin of ingredients
Physical / chemical structure (eg water activity, pH, etc)
Treatment and processing (eg heating, freezing, salting)
Packaging
Storage and distribution conditions (with specific temperatures)
Durability and required shelf-life
Instructions for use
1.5 - INTENDED USE
Intended use of product defined
End user / consumer detailed
Suitability for vulnerable groups considered (eg infants, elderly, allergen sufferers)
1.6 - FLOW DIAGRAMS
All process steps included - by product
Rework / interface included where applicable
Water included where applicable
Waste included where applicable
Flow diagram signed off as verified within the production area
CCP's are high-lighted on flow diagrams
High risk - physical barriers in process identified on flow chart
1.7 - HAZARDS
All potential hazards that may be reasonably expected to occur for each process step and product must be identified
Hazards identified must be specific to the process step - generic descriptions such as 'foreign body' and 'micro-organisms' are not sufficient
1.8 - HAZARD ANALYSIS
The HACCP team must conduct a hazard analysis to identify hazards which need to be prevented, eliminated or reduced to acceptable levels.
Hazard analysis must include - likely occurrence and severity
Hazard analysis must include - survival or multiplication of micro-organisms
Hazard analysis must include - presence or production of toxins, chemicals or foreign bodies and allergens
Hazard analysis must include - potential for adulteration / deliberate contamination
1.9 - CONTROL MEASURES
The HACCP team must assess whether an existing pre-requisite adequately controls the hazard identified
The HACCP team must consider what control measures (if any) for the remaining hazards can be applied to prevent, eliminate or reduce the risk to acceptable levels.
If no control measures have been identified the product / process must be modified so a control measure can be applied
Documentation must show links to a specific pre-requisite, must not be generic.
1.10 - DETERMINATION OF CCP'S
Codex decision tree or equivalent must be used to determine if control measures are CCP's
Documentation must show decision tree answers that determine whether it is a CCP
1.11 - CRITICAL LIMITS
Critical limits must be defined and validated to ensure that the product is safe
The process must be capable of operating consistently within the defined limits
Critical limits must be measurable and justification for their use must be documented
1.12 - MONITORING
Monitoring procedures must be established for each CCP to ensure compliance with the critical limits
The monitoring system must be able to demonstrate control and detect loss of control of CCP's
Precision limits and tolerances of monitoring equipment must be considered when defining limits eg. tolerance of temperature probes.
Monitoring procedures must contain details on how the measurements are taken and the frequency
1.13 - MONITORING RECORDS
Monitoring records must be signed by the person doing the check
Monitoring records must then be verified by an authorised person
1.14 - CORRECTIVE ACTIONS
The corrective actions to be taken when a CCP deviates from critical limits must be detailed and documented by the HACCP team.
The corrective actions must ensure that the CCP has been brought under control
The corrective action must ensure any material that may have been produced whilst the CCP was not in control is identified, isolated and a full risk assessment completed
Product and or materials must be disposed of if the safety of the product is in doubt
Any examples where risk assessment deems the product to be safe, must be submitted to Retailer TM prior to supply to retailer
The HACCP must be reviewed at the earliest opportunity following accepted deviation from the defined critical limits
1.15 - TRAINING
Personnel in the factory who monitor CCP's must have an understanding of HACCP
Personnel in the factory who monitor CCP's must have specific training against the latest version of the relevant monitoring procedure
Aspirational - all production personnel have a basic understanding of HACCP and how it relates to the area they work in - conducted separately to induction, once individuals have become familiar with the process
1.16 - VERIFICATION
The operation of the HACCP plan must be verified to confirm that it is effective ie. that individuals are actually following the stated procedures, and that the whole system including the PRP's is operating effectively - this May include:
Review of Internal audits (relevant to HACCP)
Review of customer complaints (including FB / illness)
Review of microbiological results
1.17 - VERIFICATION (2)
Aspirational - HACCP plan is verified by a 3rd party with specialist knowledge of food microbiology, food chemistry and relevant food processing technologies
1.18 - REVIEW
HACCP plan must be reviewed at a pre-determined frequency (minimum annually)
HACCP plan must be reviewed prior to changes of product / process which may affect product safety - such as;
Changes to process steps
Changes to supply or specification of raw materials
Changes to ingredients / recipe
Changes to packaging, storage our distribution
Introduction of new or modification to existing equipment
Ensure food safety through comprehensive HACCP plan review checklist
A HACCP Plan Review Checklist is a document used to review and assess the effectiveness of a Hazard Analysis Critical Control Point (HACCP) plan. It outlines the elements of the plan, identifies applicable regulations, and includes specific questions to help verify that the plan is comprehensive and compliant. The benefits of using a HACCP Plan Review Checklist include improved food safety and compliance, better risk management, and more consistent implementation of the HACCP plan. Additionally, using a Checklist can help ensure the HACCP plan is up-to-date and properly implemented. This will help to reduce the chances of food safety incidents and minimize the risks associated with foodborne illness.
The benefits of using a HACCP internal audit checklist include:
Increased compliance rates – By identifying potential hazards early on, you may encourage employees to adhere to food safety requirements even if they do not see any obvious violations. This will help keep the food system safe while reducing the cost and time spent responding to outbreaks.
Improved quality control – Properly implemented hazard analysis and critical control points (HACCP) controls allow for consistent quality products across all stages of the manufacturing process. This ensures that products meet specific specifications and are free from harmful contaminants.
Reduced risk of recalls – By tracking where ingredients come from, how they’re processed, and what steps were taken during final disposal or storage, you reduce the chances of a product recall due to contamination.
Using a HACCP internal audit checklist is an effective way to improve your food safety program overall.
Please note that this checklist template is a hypothetical appuses-hero example and provides only standard information. The template does not aim to replace, among other things, workplace, health and safety advice, medical advice, diagnosis or treatment, or any other applicable law. You should seek your professional advice to determine whether the use of such a checklist is appropriate in your workplace or jurisdiction.
