For meal prep businesses, a robust food safety program is essential to protect customers and your brand. Hazard Analysis and Critical Control Point (HACCP) is the globally recognized, preventative system at the core of modern Food Safety Management Systems (FSMS). This complete guide walks through the HACCP building blocks, the 7 principles, and a step-by-step roadmap to implement HACCP in a practical, operations-friendly way.
What Is HACCP?
HACCP is a systematic, science-based approach that identifies food safety hazards and establishes controls at specific points in the process. It shifts focus from end-product testing to prevention. HACCP commonly sits within a broader FSMS alongside prerequisite programs like sanitation, allergen control, supplier approval, and training.
Prerequisite Programs (PRPs)
Before building your HACCP plan, establish foundational programs to control general risks throughout the facility:
- Good Manufacturing Practices (GMPs) and personal hygiene
- Sanitation Standard Operating Procedures (SSOPs)
- Allergen management and label controls
- Supplier approval and incoming goods inspection
- Pest control
- Equipment calibration and maintenance
- Temperature control for storage, prep, and delivery
- Staff training and competency
The 7 Principles of HACCP
- Conduct a Hazard Analysis – Identify biological, chemical, and physical hazards for each step.
- Determine Critical Control Points (CCPs) – Steps where control is essential to prevent or reduce a hazard to an acceptable level.
- Establish Critical Limits – Measurable limits that separate safe from unsafe (e.g., time and temperature).
- Establish Monitoring Procedures – Define who, what, when, and how measurements are recorded.
- Establish Corrective Actions – Predetermine actions when monitoring shows loss of control.
- Establish Verification Procedures – Activities confirming the plan works (e.g., audits, calibration, review).
- Establish Recordkeeping – Documentation demonstrating control and due diligence.
Example Hazard Analysis
| Process Step | Potential Hazard | Preventive Measure |
|---|---|---|
| Receiving Chicken | Biological (Salmonella) | Approved suppliers, temperature on receipt ≤ 40°F (4°C) |
| Cold Storage | Growth of pathogens | Refrigeration ≤ 40°F (4°C), continuous logging |
| Cooking | Survival of pathogens | Cook to ≥ 165°F (74°C) for 15 sec |
| Cooling | Spore germination | 135°F → 70°F in 2 hours; 70°F → 41°F in 4 hours |
| Labeling | Allergen mislabeling | Allergen review, label verification, line clearance |
Determining CCPs
Use a CCP decision tree to identify steps that must be controlled to ensure safety. Typical CCPs for meal prep include cooking, cooling, and cold holding. For a deeper dive, see How to Identify Critical Control Points (CCPs) in HACCP.
Critical Limits
Critical limits must be measurable and validated. Sources include FDA Food Code, scientific studies, or process authority guidance. Examples include minimum internal cook temperatures, maximum cooling times, or storage temperature targets.
Monitoring Procedures
- What: The measurable parameter (e.g., temperature)
- How: The instrument or method (calibrated probe, data logger)
- When: Frequency (each batch, hourly, continuous)
- Who: The trained person responsible
- Records: Where the measurements are documented
Corrective Actions
Predetermine actions to take when a critical limit is not met. Typical actions include product hold, evaluation, rework, disposal, and root cause analysis with retraining. Learn more in How to Develop HACCP Corrective Actions for Allergen Risks.
Verification and Validation
- Verification: Confirms the plan is followed and effective (internal audits, record review, calibration, environmental monitoring).
- Validation: Evidence that the control measures and critical limits are scientifically sound for the intended products and processes.
Recordkeeping and Documentation
Maintain clear, legible records that demonstrate control over each CCP and PRP. Keep monitoring logs, corrective action forms, verification checklists, training logs, supplier approvals, and label reviews. Good documentation protects customers and supports regulatory compliance.
HACCP Implementation Roadmap
- Build a cross-functional HACCP team (culinary, QA, operations, delivery)
- Describe products and intended use (RTE, allergens, shelf life, distribution)
- Map process flow, confirm on site, and perform hazard analysis
- Identify CCPs and set validated critical limits
- Define monitoring, corrective actions, and verification
- Establish records and train staff
- Pilot, review results, then roll out and improve continuously
Common Pitfalls (and Fixes)
- Inadequate cooling controls: Use shallow pans, blast chillers, and track time/temperature.
- Weak allergen controls: Enforce label checks and line clearance with double sign-off.
- Missing calibration: Calibrate probes on a schedule and document it.
- Incomplete training: Build role-based SOPs and refreshers with competency checks.
Monitoring CCPs in Practice
Effective CCP monitoring keeps processes in control and simplifies investigations. See Monitoring CCPs in HACCP Plans: Procedures for practical checklists and examples.
FAQs
Is HACCP required?
Requirements vary by jurisdiction and product type. In the U.S., many operations follow HACCP principles under regulatory frameworks like the FDA Food Code or FSMA. Consult your local authority for specifics and consider guidance from the FDA or ISO 22000.
How often should a HACCP plan be reviewed?
At least annually, and whenever there are significant changes (new ingredients, equipment, suppliers, processes, or complaints/outbreak learnings).
