This is where you evaluate your processes and identify where hazards can be introduced. Hazards can be physical (i.e. metal contamination), chemical (i.e. can a cleaning product contaminate the product, are there toxins that could contaminate the product?) or biological (at what points could bacteria or virus contaminate your product?). You will need to make sure that you have the expertise to make an accurate evaluation of the hazards. This means that if you do not have sufficient expertise in your organization you will need to identify external resources that you can use to perform the hazard analysis.
The hazard identification is done in two steps, first the identification of hazards, then an evaluation of the hazard. The hazard evaluation is a determination of the degree of risk to the user from the identified hazard. Once the hazard is identified and evaluated the team must identify critical control points. These are points where the hazard must be controlled or it will present a risk to the end user.

Example Scenario: A Meat Processing Plant

1. Biological hazard: The raw beef could carry harmful bacteria like E. coli or Salmonella. These bacteria could make people sick if the meat isn’t handled properly.

2. Chemical hazard: If cleaning chemicals used in the plant accidentally come into contact with the beef, it could contaminate the meat.

3. Physical hazard: Small pieces of machinery, like metal shavings from the grinder, could accidentally end up in the meat.

A critical limit is the maximum or minimum value to which a physical, biological, or chemical hazard must be controlled at a critical control point to prevent, eliminate, or reduce that hazard to an acceptable level.

Example:

1. Let’s take the example of cooking chicken in a restaurant. A critical hazard for chicken is Salmonella, which can cause foodborne illness if not properly controlled.

Critical Limit Example: The critical limit for cooking chicken could be that the internal temperature must reach 165°F (74°C) for at least 15 seconds to ensure the bacteria are killed.

2. Refrigeration of Perishable Food

Critical Hazard: Bacterial growth in perishable foods like seafood or raw meat.

Critical Limit: Refrigerators must maintain a temperature of 40°F (4°C) or lower to prevent bacterial growth.

Scenario: In a seafood processing plant, fresh fish is stored in cold rooms set at 38°F. The plant checks the refrigeration units daily. If the temperature rises above 40°F, corrective action is taken, such as moving the fish to another properly cooled unit or discarding the compromised product.

3. Cooling Cooked Food

Critical Hazard: Bacterial growth, especially Clostridium perfringens and Bacillus cereus, which thrive when food cools too slowly.

Critical Limit: Cooked food must cool from 140°F to 70°F within 2 hours, and then from 70°F to 40°F within 4 hours.

Scenario: A large catering company prepares food in advance. After cooking, the chef ensures all food is cooled in shallow pans and placed in the refrigerator immediately. If food doesn’t cool within the set critical limits, it must be discarded to avoid bacterial contamination.

The monitoring that takes place at the critical control points is essential to the effectiveness of the HACCP program. The monitoring program will be made up of physical measurement or observations that can be done in a timely manner, to provide the information in a time frame that allows you to take action and control product if an out of control situation occurs.

Example 1: Refrigeration in  Food Processing Plant

In a food processing plant that handles perishable items like dairy or meat, refrigeration is a critical control point. The acceptable temperature limit for safe storage might be set at 40°F (4°C). To monitor this, workers would check the temperature of the refrigerators every 4 hours using a thermometer or a digital monitoring system.

The monitoring procedure could include:

• Recording the temperature in a logbook or system.

• If the temperature goes above 40°F, taking immediate corrective actions, such as adjusting the fridge settings or moving the food to another cooler.

You will establish what actions need to be taken if a critical limit is not met. This will be identified ahead of time for each CCP. The action must make sure that no unsafe product is released. There must also be an evaluation of the process to determine the cause of the problem and an elimination of the cause.

The action or actions taken have two purposes, to control any nonconforming product resulting from the loss of control, and to identify the cause, eliminate it and prevent the situation from reoccurring. By identifying the corrective action before an out of control situation occurs, you are prepared to take action quickly if and when it does occur. It's part of the HACCP system that ensures food is safe to eat by identifying and fixing issues before they lead to unsafe food. 

Example:

Imagine a restaurant has a HACCP plan to keep food at the correct temperature to prevent bacteria growth. One critical control point is ensuring that cooked chicken is stored at a temperature below 40°F (4°C) in the fridge.

What could go wrong?

One day, the fridge breaks, and the temperature rises to 50°F (10°C), which is too warm. This is a problem because bacteria can grow at this temperature, making the chicken unsafe to eat.

Corrective Action:

The corrective action would be to discard the chicken that was exposed to unsafe temperatures. Then, the fridge needs to be repaired immediately or food should be moved to another properly functioning fridge.

You will determine what records are needed to show that the critical limits have been met, and the system is in control. Address regulatory requirements and include records from the development of the system and the operation of the system.

Example:

A restaurant follows HACCP protocols to avoid foodborne illnesses. One critical point is ensuring that chicken is cooked to a safe internal temperature (at least 165°F). The restaurant staff uses a thermometer to check the temperature of each batch of chicken. After cooking, they log the time and temperature in a record-keeping system, either digitally or on paper. If an inspector visits, the restaurant can show the log to prove that the chicken was cooked properly, ensuring safety. 

The HACCP plan must be validated. Once the plan is in place, make sure it is effective in preventing the hazards identified. Test the end product, verify that the controls are working as planned. Perform ongoing verification of the system. Are measuring and monitoring equipment in control? What are corrective actions showing? Are records being maintained as required?

Example:

A company that produces bottled juice. One of the critical control points (CCPs) identified in their HACCP plan is the pasteurization process, which kills harmful bacteria.

Verification Procedures for this CCP might include:

• Reviewing temperature records: Ensure that the juice is always heated to the correct pasteurization temperature (e.g., 71°C for 15 seconds).

• Calibrating thermometers regularly: Ensure that the thermometers used to monitor pasteurization are accurate and working properly.

• Microbial testing: Periodically test samples of the juice after pasteurization to verify that no harmful bacteria remain.

For example, every month, the company might send samples of the pasteurized juice to a lab to confirm that it’s free from bacteria like E. coli or Salmonella. If the test shows bacteria, they investigate and fix the issue immediately.