# 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)

```mermaid
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