Food safety is the foundation of public health; however, numerous inspections reveal alarming gaps in the supervision system. Particularly concerning is the long-term approval of products for market circulation that have not undergone reliable verification and, in some cases, even contained prohibited ingredients harmful to health. Audits conducted by the Supreme Audit Office (NIK) have shown that inspections often focus solely on checking the limits of individual food additives, while overlooking their cumulative effects and interactions, which poses a real threat to consumers.

Today, the HACCP system is the cornerstone of food safety, enabling the precise identification, control, and assessment of hazards. These hazards fall into three main categories: physical, chemical, and microbiological. The HACCP system helps manufacturers proactively prevent potential issues before they affect the quality and safety of the final product.

Effective food safety management requires a comprehensive approach that covers both raw materials and the entire production process. The HACCP system identifies critical control points where hazards can be effectively eliminated. Investing in this system is not only about meeting legal requirements, but above all about caring for consumer health and building trust in the brand.

In Poland, the food safety control system operates, among other things, based on HACCP audits, which are also used internally by food processing companies. In this article, you will learn what HACCP is and how to conduct HACCP audits with the highest level of accuracy. Read on to find out more.

What Is HACCP?

To ensure the highest food safety standards, the European Union published the White Paper on Food Safety in January 2000, outlining a comprehensive strategy in this area. A key element of this strategy was Regulation (EC) No 178/2002 of the European Parliament and of the Council of 28 January 2002, which laid down the general principles and requirements of food law. An important complement is also the Regulation of the European Parliament and of the Council (EU) on the provision of food information to consumers.

The main objectives of these regulations are:

• Protection of consumer health
• Ensuring consumers’ right to full information about the food they consume, enabling them to make informed choices

It must be clearly emphasized that the implementation of the HACCP system is only possible after the prior implementation and consistent application of Good Manufacturing Practice (GMP) and Good Hygienic Practice (GHP). These two elements are fundamental to effective food safety management.

What Hazards Does the HACCP System Prevent?

There are three main categories of hazards in the food industry: microbiological, chemical, and physical. In the HACCP system, a hazard is defined as any factor that may cause food to become unsafe. The system focuses on identifying and controlling these hazards to ensure food safety.

Below are examples of hazards identified by the HACCP system, along with their descriptions.

Microbiological Hazards

Microbiological hazards represent the main risk in food production, as microorganisms such as bacteria, viruses, and molds can cause foodborne illnesses. The sources of these hazards are diverse and include people (staff, visitors), animals (rodents, insects, birds), and the environment (tools, clothing, restrooms).

Examples include pathogens such as Salmonella and E. coli. Controlling these hazards requires strict personal hygiene, as well as regular disinfection and temperature control to prevent the spread of microorganisms.

Chemical Hazards

Chemical hazards result from the presence of harmful chemical substances in food. These may occur naturally, such as toxins produced by certain organisms, or be introduced intentionally or accidentally, for example through pesticide use, heavy metals, or food additives.

Key examples include pesticides, heavy metals (lead, mercury), and preservatives. Controlling these hazards requires careful supplier control, proper storage of chemicals, and regular monitoring of chemical residues in products.

Physical Hazards

Physical hazards involve the presence of foreign objects in food that may cause physical injury to the consumer. These may occur naturally, such as bones or fish bones, or be introduced from external sources, such as glass fragments, metal shavings, or plastic pieces.

Control measures include regular visual inspections, the use of metal detectors, and routine equipment maintenance. Eliminating these hazards is essential to ensure consumer safety and prevent potential injuries.

The 7 Principles of HACCP

The HACCP system (Hazard Analysis and Critical Control Points) is a pillar of food safety and is based on seven key principles. These principles provide a systematic approach to identifying, assessing, and controlling hazards that may occur at every stage of food production. Their goal is to ensure that food is safe for consumers.

1. Identification and analysis of all potential hazards at every stage of the process
   This is the first and most critical step, involving a thorough analysis of the entire production process—from raw material intake to distribution of the finished product. All potential biological, chemical, and physical hazards must be identified at each stage.
2. Determination of Critical Control Points (CPs and CCPs)
   Critical Control Points (CCPs) are points in the process where control is essential to prevent or eliminate a hazard. These points must be clearly identified, and stages that are critical to food safety must be defined.
3. Establishment of critical limits and acceptable tolerance levels for each CP and CCP
   For each CCP, specific critical limits must be established to determine whether the process is under control. These limits must be measurable and based on scientific evidence.
4. Establishment of monitoring procedures for each CP and CCP
   Monitoring involves regular measurement and recording of data related to CCPs. It must be defined who monitors, how often, and in what manner each CCP is monitored.
5. Definition of corrective actions to be taken when critical limits are exceeded
   If critical limits are exceeded, immediate corrective actions must be taken to bring the process back under control. The actions to be taken in each situation must be clearly defined.
6. Establishment of verification procedures for the HACCP system
   Verification involves regular checks to ensure that the HACCP system is functioning properly. Internal and external audits should be conducted to confirm system effectiveness.
7. Development of HACCP system documentation
   Detailed documentation must be maintained for all aspects of the HACCP system, including hazard analysis, CCP identification, monitoring, corrective actions, and verification. Documentation is essential to demonstrate that the system is operating correctly.

HACCP Principles: Practical Examples

HACCP is not only a legal requirement but, above all, a guarantee of quality and safety. To better understand how to apply this system effectively, below are practical examples from different stages of food production.

Example 1: Receiving goods at the warehouse

The key hazard is damaged packaging, which may lead to product contamination. To prevent this, visual inspection of packaging is carried out with each delivery. Monitoring involves assessing the condition of packaging, and corrective action consists of rejecting goods with damaged packaging in accordance with established procedures.

Example 2: Storing meat in refrigeration units

The main hazard is incorrect temperature, which may promote bacterial growth. Preventive action involves maintaining the cold storage temperature between 2°C and 4°C. Monitoring includes measuring the temperature every 12 hours. In the event of deviations, corrective actions such as temperature adjustment are taken.

Example 3: Thermal processing of food

The hazard is insufficient processing temperature, which may result in inadequate destruction of microorganisms. Preventive action includes controlling the cooking temperature and maintaining it below +100°C, with a tolerance of ±7°C. Monitoring involves checking the food temperature during thermal processing. If the temperature is insufficient, the corrective action is to extend the processing time.

How to Conduct an HACCP Audit

Conducting an HACCP audit is a key element in maintaining high food safety standards. The following steps should be taken to perform an effective HACCP audit:

• Audit preparation: The audit process begins with careful preparation, including defining the audit objectives and scope. This involves creating a detailed schedule and collecting the necessary documentation, such as the HACCP plan, procedures, and monitoring records.
• Conducting the audit: During the audit, the audit team carries out activities to assess the compliance of the HACCP system with established standards. This includes reviewing documentation as well as observing production processes.
• Preparing the audit report: After the audit is completed, the audit team prepares a detailed report summarizing the findings. The report includes information on compliance and, most importantly, identifies non-conformities and provides recommendations for corrective actions.
• Implementation of corrective and preventive actions: The final stage of the audit involves implementing corrective and preventive actions to eliminate identified non-conformities. It is essential to monitor the effectiveness of these actions and conduct a follow-up audit to ensure that the HACCP system operates correctly and effectively prevents food safety hazards.

A System for Automating HACCP Audits

auditomat® is a modern system that streamlines the audit process in organizations. The auditomat® system can be successfully used for HACCP audits (Hazard Analysis and Critical Control Points). Key aspects include:

• Monitoring food safety standards: The system enables the creation of checklists and audit lists that incorporate all HACCP requirements. It allows monitoring of critical control points (CCPs) and identification of potential hazards.
• Documentation and reporting: Automatic generation of audit reports ensures complete documentation of conducted audits. Data centralization facilitates analysis and identification of areas requiring improvement.
• Regulatory compliance: The system helps maintain compliance with food safety regulations and supports the responsibilities of compliance specialists in the context of HACCP.

Summary

HACCP is a system for identifying, assessing, and controlling hazards that may occur in the food production process. It is based on seven key principles, including hazard analysis, identification of critical control points (CCPs), establishment of critical limits, monitoring, corrective actions, verification, and documentation.

Modern tools such as auditomat® can significantly improve this process by automating audits, centralizing data, and ensuring compliance. Investing in an effective HACCP system is an investment in consumer health and brand trust. Schedule a presentation of the auditomat® system—our experts will show you how to automate HACCP audits and increase the efficiency of food safety management.