HACCP Checklist

What is HACCP?

HACCP (Hazard Analysis and Critical Control Points) is a systematic, science-based approach to food safety that identifies, evaluates, and controls hazards throughout the food production process. Developed in the 1960s for NASA's space program, it is now a global standard (Codex Alimentarius).

The system is built on 7 principles: (1) Conduct hazard analysis, (2) Determine Critical Control Points (CCPs), (3) Establish critical limits, (4) Establish monitoring procedures, (5) Establish corrective actions, (6) Establish verification procedures, (7) Establish documentation. Prerequisites like GMP and SSOP must be in place before HACCP implementation.

CCPs are points in the food process where control can be applied to prevent, eliminate, or reduce a food safety hazard to acceptable levels. Common CCPs include cooking temperature (killing pathogens), cooling rate (preventing growth), and metal detection (physical hazards).

The distinction between CCPs and operational prerequisite programs (oPRPs) is important. Not every control point is a CCP — only those where loss of control would directly result in an unsafe product. oPRPs are control measures for hazards that are less severe or less likely, managed through procedures rather than real-time monitoring. Overidentifying CCPs dilutes focus and increases monitoring burden.

Formula: CCP Decision Tree: 1. Does a control measure exist? → If No, modify process 2. Is the step specifically designed to eliminate/reduce hazard? → If Yes, CCP 3. Could hazard occur above acceptable levels? → If No, not CCP 4. Will a subsequent step eliminate the hazard? → If Yes, not CCP → If No, CCP

Example: Cooking CCP

For chicken, the cooking step is a CCP with a critical limit of 74°C (165°F) internal temperature for 15 seconds to eliminate Salmonella. Monitoring: check temperature of each batch with a calibrated probe thermometer. Corrective action: continue cooking if temperature is not met; reject product if time exceeded.

When to Use This Calculator

• Food safety managers conducting internal audits to verify that all critical control points are monitored and documented per the HACCP plan
• New food business operators setting up their initial HACCP system and needing a comprehensive checkpoint reference by process stage
• Training new food handlers on the specific checkpoints, critical limits, and corrective actions for each stage of food production
• Third-party auditors using the checklist as a structured guide when assessing HACCP compliance during BRC, SQF, or FSSC 22000 audits

Common Mistakes to Avoid

• Identifying too many CCPs — overloading the plan with non-critical control points dilutes monitoring effort and makes the system unmanageable; use the CCP decision tree rigorously to distinguish CCPs from oPRPs
• Setting critical limits without scientific basis — critical limits must be based on regulatory requirements, published scientific literature, or validated in-house studies; arbitrary limits provide false assurance
• Monitoring without corrective action follow-through — recording a CCP deviation without executing the documented corrective action (hold, investigate, dispose) defeats the purpose of the HACCP system
• Treating the HACCP plan as a static document — plans must be updated when products, processes, equipment, suppliers, or regulations change; an outdated plan is as dangerous as no plan
• Neglecting prerequisite programs — HACCP cannot compensate for inadequate basic hygiene; if cleaning, pest control, or personal hygiene programs are weak, CCPs will fail regardless

Related Standards & References

• Codex Alimentarius General Principles of Food Hygiene (CXC 1-1969, Rev. 2020) — International foundation for HACCP, adopted by WHO/FAO
• EU Regulation 852/2004 — Hygiene of foodstuffs, requiring HACCP-based procedures for all food business operators in the EU
• FDA FSMA Preventive Controls for Human Food (21 CFR Part 117) — US regulation requiring hazard analysis and risk-based preventive controls
• ISO 22000:2018 — Food Safety Management Systems, integrating HACCP with management system requirements
• BRC Global Standard for Food Safety (Issue 9) — GFSI-benchmarked certification standard incorporating HACCP as a core requirement

Frequently Asked Questions

Is HACCP mandatory?

HACCP is mandatory for food manufacturers in the EU (Regulation 852/2004), US (FSMA for most facilities), Canada, Japan, and many other countries. Even where not legally required, HACCP is a prerequisite for most food industry certifications (BRC, SQF, FSSC 22000) and retail customer requirements.

What is the difference between HACCP and ISO 22000?

HACCP provides the core food safety principles. ISO 22000 is a broader Food Safety Management System that incorporates HACCP principles along with management system elements (similar to ISO 9001), prerequisite programs, and interactive communication throughout the food chain. ISO 22000 certification encompasses HACCP compliance.

How often should HACCP plans be reviewed?

HACCP plans must be reviewed whenever there is a change in product, process, equipment, packaging, or regulations. At minimum, an annual verification review is standard practice. Additionally, any food safety incident, customer complaint, or audit non-conformance should trigger an immediate plan review for the affected process.

What are prerequisite programs (PRPs) and why are they important?

PRPs are basic hygiene and operational conditions that must be in place before HACCP can function — including cleaning and sanitation (SSOP), pest control, personnel hygiene, equipment maintenance, supplier control, and allergen management. Without effective PRPs, the HACCP plan cannot function because the baseline food safety conditions are not met.