Hazard Analysis & HACCP Plan

ISO 22000:2018 (FSMS) core – hazard analysis per Codex HACCP principles. Identify hazards across the process, classify control measures as OPRP or CCP, monitor, correct, verify.

Field	Value
Document ID	DOC-FSMS-020
Product/process	name
HACCP team	members (multidisciplinary required)
Date	YYYY-MM-DD

1. Product & intended use

• Product description, composition, packaging, shelf life
• Intended use + vulnerable consumer groups
• Process flow diagram (verified on site – required step)

flowchart LR
    R[Receiving] --> S[Storage] --> P[Prep] --> C[Cooking CCP] --> K[Cooling CCP] --> Pack[Packaging] --> D[Distribution]

2. Hazard analysis (per process step)

Step	Hazard (bio/chem/phys/allergen)	Likelihood	Severity	Control measure	Type
Receiving	Pathogens in raw material	M	H	Approved suppliers + COA	OPRP
Cooking	Survival of pathogens	L	H	Time/temp cook	CCP
Cooling	Spore germination	M	H	Cooling rate control	CCP
Packaging	Metal fragments	L	M	Metal detector	CCP
Storage	Allergen cross-contact	M	H	Segregation + labeling	OPRP

3. CCP monitoring plan

CCP	Hazard	Critical limit	Monitoring (what/how/when/who)	Correction	Records
CCP-1 Cooking	Pathogen survival	≥75C core, ≥2min	probe, each batch, operator	re-cook / discard	cook log
CCP-2 Cooling	Germination	60→10C in ≤4h	logger, each cycle, supervisor	extend cooling	cooling log
CCP-3 Metal detect	Metal	2.0mm Fe / 2.5mm nonFe	test wands, hourly, QA	hold + inspect product	detector log

4. OPRP controls

OPRP	Hazard	Action criterion	Monitoring	Correction
Supplier approval	Raw material safety	approved list + COA	each delivery	reject lot

5. Verification & validation

• Validation: evidence limits work (literature, challenge testing)
• Verification: calibration, internal audits, micro testing, review
• Nonconforming product handling + recall/withdrawal procedure