HACCP Compliance: Software Enhances Food Safety & Allergen Programs
Jennifer Kinion
Hazard Analysis and Critical Control Points, or HACCP, is the system by which food manufacturers and processors preventively address chemical, physical, and biological hazards. Hazards must be controlled through every step of the supply chain, which includes sourcing raw material production, procurement, handling, manufacturing, and distribution. Of course, safety and quality teams within food and beverage companies are already familiar with HACCP plans, but they may not have considered software that helps them with the execution and monitoring of HACCP.
According to the International HACCP Alliance, effectively managing a HACCP plan requires companies to:
Perform a thorough hazard analysis
Identify critical control points (CCPs)
Establish critical limits for preventive measures
Determine CCP monitoring requirements
Set corrective actions for out-of-spec CCPs
Follow effective record keeping procedures to document HACCP system effectiveness
Establish procedures to verify the HACCP system is working properly
For companies with extensive product lines or paper-based systems, fulfilling each of those steps can become challenging.
Why Digitize HACCP Execution & Monitoring
HACCP execution and monitoring software for food companies is designed to help manage robust safety and quality programs, required by most customers, 3rd parties, and regulatory bodies, such as GFSI, USDA, and NSF. Compliance requirements, workflows, and tasks can be organized and managed in one centralized system.
Additionally, the volume of records produced by a HACCP plan can be difficult to manage. Paper-based systems present a number of risks; records can go missing, paperwork can be incomplete, and investigations can last hours. Physical forms, binders, and spreadsheets also allow for human error and make it easier to overlook non-compliant data.
Software designed exclusively for food companies can store all of your food safety protocols, as well as regulatory data, customer quality requirements, and GFSI scheme documentation. FSQA teams can define workflows so that when program tasks need to be completed or results are out-of-spec, alerts will notify management and issues can be addressed promptly. Digitized compliance data allows FSQA management to track performance both in real-time and on an ongoing basis to help determine the effectiveness of a HACCP plan, and pinpoint which areas need improvement.
Achieve HACCP Plan Automation
HACCP is a complex system with many different components, including:
hazard analysis
identification of critical control points
establishing maximums and minimum limits for processing or manufacturing characteristics
establishing critical limits
monitoring procedures
and corrective actions.
Completing, monitoring, and verifying all these processes is exceptionally time and labor-intensive, especially when obsolete recordkeeping systems like paper logs and binders are used. Instead of manually entering data, companies can now leverage dynamic mobile forms to capture CCP data from operators across different processes, and visualize CCP data in real-time so records don’t deviate from control limits.
In-process verification of CCP data is a large component of executing a HACCP plan, but quick investigation of non-compliant data after a customer complaint or supplier issue is also crucial. Quick investigation and informed root cause analysis rely on a precise digital trail of quality data and clear SOPs. Automated workflows take away any guesswork or latency between an issue and corrective action.
Enhance Visibility
Increased scrutiny from auditors and customers means that HACCP plans must be reviewed consistently, and flexible enough to update relatively easily. Manual, paper-based HACCP monitoring systems are prone to human error and data entry inconsistencies, making it difficult to ensure that everyone is working with the most current information. Transitioning to a digital platform centralizes all HACCP data, ensuring that the entire team has access to the latest records and procedures.
Digital tools also enhance visibility into HACCP performance, offering real-time insights through reports and dashboards. These tools allow you to track key metrics at the plant level, such as temperature and critical control points, or across multiple plants, ensuring consistent quality standards for the whole enterprise.
What About Allergen Control Programs?
HACCP allergen control programs are designed to help food and beverage facilities minimize allergen-related risks proactively. The objective is to identify potential risks, develop controls, and put established controls in place to prevent cross-contamination, mislabeling, and any other potential issues that might occur in production or packaging. While a standard HACCP approach may work for most companies, some companies may want to take another look at their allergen control program to ensure full effectiveness.
Here are a few things you can do to take extra precautions:
1. Review the Big 8
The FDA has outlined eight key categories of allergens: milk, eggs, fish, crustacean shellfish, tree nuts, peanuts, wheat, and soybeans. While some of these are standalone categories, it’s important to note that there are many more foods that can also fall into some of these groups. More than 170 foods have reportedly led to allergic reactions, so food companies should carefully review their ingredients to ensure nothing has been overlooked. For instance, crab, lobster, and shrimp are all encompassed by the crustacean category, while almonds, walnuts, and pecans are just a few different types of tree nuts.
2. Obtain Suppliers’ Food Safety Plans
It is recommended that importers request a copy of their foreign suppliers’ food safety plan. This will allow you to verify everything is in place to satisfy FSMA’s Preventive Controls rule, along with allergen control plans. It’s also important to review any products that could be hidden, such as eggs, milk, wheat, and soybeans used to create processed products.
3. Update Consumers & Customers
Any time an ingredient or process is changed that could pose an allergen-related risk, it’s important to let consumers know. Groups like FARE (Food Allergy Research & Education) invite manufacturers to send notifications about ingredient changes to help ensure any consumers who could be affected are made aware of the change in advance.
Growing Business With Better HACCP Control
Transitioning from manual HACCP processes to a centralized digital system offers food and beverage companies significant benefits. A platform that enhances visibility, ensures accuracy, and simplifies the execution of safety and quality programs puts your company in a place to compete for larger contracts and secure more business. Auditors and GFSI inspectors (SQF, BRC, etc) are requiring more data and higher audit scores for certification. What’s more, many big retailers (Whole Foods, Costco, Albertson’s, etc) are looking for scores of 96+ or E on GFSI audits, and will likely only give you two chances to pass.
By automating data collection, monitoring critical control points, and ensuring real-time access to records, food manufacturers can more effectively manage compliance requirements and minimize risks. Implementing HACCP execution and monitoring software not only streamlines operations but supports a proactive approach to food safety, helping companies meet regulatory standards while achieving consistent product quality.
