Generic HACCP: Flow Diagram, Hazard-Analysis and HACCP Plan Worksheets

A flow diagram and worksheets are recommended in documenting the hazard analysis and final HACCP plan.

 The accuracy of the flow diagram is critical in conducting a hazard analysis. Experience has shown that
the five items listed in the basic flow diagram (below) need to be addressed in establishing a HACCP
system. The product flow diagram for salmon fillets is included as a model.
 The hazard analysis should contain information to justify the identification of the proper critical control
points.
 Information in the HACCP plan must explain the details for each HACCP step.

There is no standardized or mandated format for the flow diagram or worksheets; however the information
should be arranged in a progression that clearly explains the thought process for the hazard analysis and the
individual steps in the HACCP plan.

The following Flow Diagram, Hazard-Analysis and HACCP plan worksheets are provided as recommended
examples. The first page of the Hazard-Analysis and HACCP Plan worksheets include space for information
that must be on the forms: firm name and location of the processor or importer; product description and
signature and date (HACCP Plan). Quite often, worksheets require more than one page. Additional pages
should be numbered to correspond with the progression of the flow diagram.

To view examples of completed of flow diagrams and completed worksheets refer to the HACCP: Hazard
Analysis and Critical Control Point Training Curriculum, 4th ed., developed by the National Seafood HACCP
Alliance for Training and Education or visit the following web sites:
http://nsgd.gso.uri.edu/ncu/ncue98001.pdf (HACCP Training Curriculum, 3rd ed.)
http://seafood.ucdavis.edu/haccp/Plans.htm (Generic HACCP Plans)

References:

1. FDA.2001. Fish and Fishery Products Hazards and Controls Guidance, 3rd ed. Department of Health and
Human Services, Public Health Service, Food and Drug Administration, Center for Food Safety and
Applied Nutrition, Office of Seafood, Washington, DC. Guidance available from IFAS Extension
Bookstore, Building 440 Mowry Road, P.O. Box 110011, Gainesville, FL 32611. http://IFASbooks.ufl.edu
Phone: 352/392-1764.

2. National Seafood HACCP Alliance for Training and Education. 2001 HACCP: Hazard Analysis and Critical
Control Point Training Curriculum, 4th Edition, November 2001, p. 172-176. Curriculum available from
IFAS Extension Bookstore, Building 440 Mowry Road, P.O. Box 110011, Gainesville, FL 32611.
http://IFASbooks.ufl.edu Phone: 352/392-1764.

Adapted by Pamela D. Tom (Program Representative) and Robert J. Price (Extension Specialist, Seafood
Products) Food Science & Technology, University of California, Davis, CA 95616-8598

UCSGEP 02-9W; August 2002

This work is sponsored in part by NOAA, National Sea Grant College Program, Department of Commerce,
under grant number NA06RG0142, project number A/EA-1, through the California Sea Grant College Program,
and in part by the California State Resources Agency. The U.S. Government is authorized to reproduce and
distribute reprints for governmental purposes.
Basic Flow Diagram

Incoming Materials

Processing

Packaging

Storage

Distribution
 Sample Product Flow Diagram (Salmon Fillets)

Grate Parmesan cheese and

Receiving ingredients cut romaine lettuce and
onions

 

Sort and sample the Gently mix them with

ingredients cherry tomatoes and
smoked salmon

 

Package the salad into

Refrigerate ingredients plastic boxes with the
separately packaged
dressing

 

Prepare salad dressing Weigh the salad box

 

Wash eggs and anchovy Refrigerate under 4°C

 

Fillet the anchovy and mash Ship with truck with

to paste, mix with egg yolks refrigeration
and other ingredients

Refrigerate the dressing in

plastic cups, wait for
packaging

Disinfect and wash the

vegetables (romaine lettuce
and cherry tomatoes)
HAZARD-ANALYSIS WORKSHEET
(at least 10 hazards to be identified)

Firm Name: Hazard target: Customer

Firm Address: Date of assessment

Student name:

(1) (2) (3) (4) (5) (6)

Hazard identified Identify potential hazards Are any Justify your decisions What preventative measures Is this step
introduced, controlled or potential for column 3. can be applied to prevent the a critical
enhanced at this step (1) food-safety significant hazards? control
hazards point?
significant? (Yes/No)
(Yes/No)
Biological

Chemical

Physical

Biological

Chemical

Physical

Biological

Chemical

Physical

Biological

Chemical

Physical

Page 1 of ____
 HAZARD-ANALYSIS WORKSHEET (continued)
(1) (2) (3) (4) (5) (6)
Hazard identified Identify potential hazards Are any Justify your decisions What preventative measures Is this step
introduced, controlled or potential for column 3. can be applied to prevent the a critical
enhanced at this step (1) food-safety significant hazards? control
hazards point?
significant? (Yes/No)
(Yes/No)
Biological

Chemical

Physical

Biological

Chemical

Physical

Biological

Chemical

Physical

Biological

Chemical

Physical

Biological

Chemical

Physical

Biological

Chemical

Physical

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 HACCP Plan Form

Firm Name: Vet Food Ltd. Product Description: Caesar salad with smoked salmon, cherry tomato and onion

Firm Address: No. 83, Tat Chee Road, Kowloon Tong Method of Storage and Distribution: Stored under 4°C and transported by truck with
refrigerator
Name of student: Chu Ka To, Toby
Intended Use and Consumer: Will be sold as boxed salad at university cafeteria

(1) (2) (3) (8) (9) (10)

Critical Significant Critical Limits for Monitoring Corrective Actions Verification Records
Control Point Hazards each Preventive
Measure
(4) (5) (6) (7)
What How Frequency Who
Appropriate Improper Onions and lettuce Temperature Thermome For Driver and A full temperature Once the temperature A whole logbook of data
transit and storage should be stored and ter and storage, the worker record has to be and humidity fall out of including temperature
storage conditions within 0°C and humidity humidity once per responsible provided by the driver range, workers should and humidity is very
conditions and shorten 1.1°C, cherry meter hour; for for receiving (could be generated by report to manager at helpful for tracing back
(temperature shelf life of tomatoes should be transit, computer); in storage once; the manager to error if there is any
and humidity) fruits or stored at 13 to 18°C acquire facilities, a computer should also randomly
vegetables; the log system should be check it him/herself to
food stored from the adopted to adjust make sure data are not
at wrong driver humidity and made-up
conditions temperature
can spoil
easily

Import of Romaine Ingredients should Presence of Randomly Every Lab assistant If the food ingredients Outsource the food A computer spreadsheet
ingredients lettuce was test negative fore microbes or sample the batch or in the test positive to some sampling tasks to third should be used to record
carrying found to hazardous pathogens, ingredients once corporation listed microorganisms party food laboratory to all sampling results, and
pathogens carry E. coli pathogens like E. CPU of the in food lab every few or or pathogens, salad ensure unbiased food that facilitated tracing
O157, coli O157, Listeria microorgani for every batches outsourcing should be recalled testing. Compare the back should incidents
Listeria in sp. etc. For other sms on food batch food lab staff from university; we results to the happen. Moreover, this is
smoked microbes like items should contact verification provided by crucial for us to choose a
salmon and Salmonella, which suppliers at once to supplier to see if they trustworthy supplier with
Parmesan is prevalent in on locate the source of match or not little incident which we
cheese that eggshell, the CPU contamination and can rely on for long term
could be should be low request clean
lethal ingredients

Signature of student: Date:

Page 1 of ____
 HACCP Plan Form (continued)
(1) (2) (3) (8) (9) (10)
Critical Significant Critical Limits for Monitoring Corrective Actions Verification Records
Control Point Hazards each Preventive
Measure
(4) (5) (6) (7)
What How Frequency Who
Sorting Improper Sort out ingredients Whether Allocate Ideally, Inventory If packaged food is Chefs or food Record all the reported
different mixing when before putting them ingredients workers to every time manager and mixed up, place them processors should report incidents and also the
ingredients storing the into storage. In are mixed check the when a the workers back to correct mixing up of severity of them.
into places food allows general, vegetables together inventory worker locations. For severe ingredients at once, so
and store them cross- and meat products when to ensure needs to contamination (e.g. that we can verify if
separately contaminatio have to be stored. the points take unpacked food), inventory workers are
n, e.g. separated. Ideally, Ingredients mentioned something discard the food with doing their job or not.
storing eggs ingredients of with in (4) from suspected We can also refer to the
and salmon different batches different fridge. At contamination and incident rate of
together may should also be expiry date least a report incidents to improper sorting of
contaminate distinguished from should also daily allow correction next ingredients for monthly
salmon with each other be inventory time review
Salmonella, separated check has
and they can to be
grow rapidly done.
with good
nutrition

Washing and Vegetable Follow the If the Randomly Random Senior chefs If workers are found to List the disinfection Manager can record any
disinfecting ingredients instructions of usage disinfectant check the frequency, or the be unfamiliar with the requirements for inadequate disinfection
ingredients like lettuce of food disinfectant: is preparation approxima quality disinfection process, different food items in and remind the workers.
before use and eggs ensure adequate concentrate room and tely once control he or she should be preparation room, so A logbook should also be
contain strength and time of d enough time the a few days manager trained again in this that workers can refer to present on spot to allow
microbes on disinfection of food and if the process, see aspect. Food that are it anytime. Can also workers to record their
surface. items before using time of also if the inadequately introduce a logbook own procedures
Indeed, them, especially disinfection workers are disinfected should be regarding the record of
Salmonella food is raw in salad. is long diluting the disinfected again disinfection so that the
contaminatio Also use the enough detergent before actually used in manager can check if
n in raw ingredients at once correctly dishes. the disinfection
eggs often or they are exposed procedures are up to
comes from to contamination standards
the eggshell once again
without
washing
thoroughly

Page ____ of ____

 HACCP Plan Form (continued)
(1) (2) (3) (8) (9) (10)
Critical Significant Critical Limits for Monitoring Corrective Actions Verification Records
Control Point Hazards each Preventive
Measure
(4) (5) (6) (7)
What How Frequency Who
Ensuring Utensils like Disinfect and wash If the water Install a Constant Workers in If after washing, Monitor the computer Computerized recording
utensils used chopping utensils with high in washing electronic checking, washing area workers find out that record of water system with electronic
are clean and boards and pressure and high area is of thermomete should be water temperature was temperature and log
disinfected graters are temperature boiling r and water maintaine too low, they should pressure to confirm
considered (preferably 100°C point and heater to d all the redo the process with water used to wash
ideal places boiling water) to whether the allow day boiling water later dishes is of high
for bacterial ensure no food water constant temperature and high
growth, substance remains temperature heating of pressure
since the on utensils, like is high water,
cleaning of cheese sticking to enough heater
them are the grater should be
often not powered up
thorough if the
and food temperature
substance falls before
might be left a point
on the
utensils even
after
cleaning
Shelf life of Even under Strictly follow the See if food Workers Every day Chefs and If expired food is used Inventory manager Manager can put a big
the proper shelf life guidance. items are should pay workers anyone in salad, we should should post a general sign with expiry dates on
ingredients refrigeration, Never use food that expired or attention to should involved in recall all affected food guidance for shelf life ingredients, so that
ingredients has passed the not before the expiry ensure no food at once. Easily spoiled for every food expiry dates are obvious
like opened expiry date. using them date sign expired processing opened food should be ingredient in fridge. He and clear to every food
onion, Moreover, be extra on food is well sealed after use to and his team should processor. If he finds out
tomatoes careful about ingredients. left in the ensure spoilage is also be responsible for the import of expired
and anchovy opened packaged Never use fridge, limited managing the fridge food, he should let the
have a short food, like opened expired workers every day to ensure no general manager know at
shelf life. smoked salmon, food items. should expired food is left once and report the
Spoiled their shelf life might double inside. incident to the supplier.
ingredients be shorter after check
can be being exposed before
hazardous to using an
food safety ingredien
of the salad t
product

Page ____ of ____

 HACCP Plan Form (continued)
(1) (2) (3) (8) (9) (10)
Critical Significant Critical Limits for Monitoring Corrective Actions Verification Records
Control Point Hazards each Preventive
Measure
(4) (5) (6) (7)
What How Frequency Who
Ensuring Utensils like Disinfect and wash If the water Install a Constant Workers in If after washing, Monitor the computer Computerized recording
utensils used chopping utensils with high in washing electronic checking, washing area workers find out that record of water system with electronic
are clean and boards and pressure and high area is of thermomete should be water temperature was temperature and log
disinfected graters are temperature boiling r and water maintaine too low, they should pressure to confirm
considered (preferably 100°C point and heater to d all the redo the process with water used to wash
ideal places boiling water) to whether the allow day boiling water later dishes is of high
for bacterial ensure no food water constant temperature and high
growth, substance remains temperature heating of pressure
since the on utensils, like is high water,
cleaning of cheese sticking to enough heater
them are the grater should be
often not powered up
thorough if the
and food temperature
substance falls before
might be left a point
on the
utensils even
after
cleaning
Limit and During The plastic Tests A quality Every Packaging If anything regarding Regularly sample the Keep tracks of all the
prevent packaging, containers should be should be control time when staff the quality of plastic plastic container for chemical and biological
contamination contaminatio free of harmful done to document we pack container goes wrong, harmful chemical tests done and record
during n might chemicals like show that must be salad into we should stop using it substance and do them into a spreadsheet.
packaging come into plasticizers or the provided boxes at once and switch to microbial swap on
place, i.e. carcinogenic containers by the paper boxes. Make brand new containers to
the plastic substance. It should are free of container sure the plastic ensure they are “clean”.
disposable also be sealed certain supplier to containers are up to Monitor the storage of
containers before use so that it substances, ensure the standards for the containers in our
could be is free from it should be safety of future supply. If failed, facilities so that they are
contaminate microbial disinfected plastic. we should look for less likely to be
at first place contamination before use Containers another container contaminated.
and food put (e.g. by UV should supplier.
inside will radiation) ideally be
be disinfected
contaminate, by
e.g. ourselves
chemical before use
residue or
microbes

Page ____ of ____

 HACCP Plan Form (continued)
(1) (2) (3) (8) (9) (10)
Critical Significant Critical Limits for Monitoring Corrective Actions Verification Records
Control Point Hazards each Preventive
Measure
(4) (5) (6) (7)
What How Frequency Who
Cold chain Cold chain As aforementioned Temperatur Check the For fridge, Inventory If the food has been Workers or drivers Manual or computerized
maintenance might be different ingredients e should be temperature once per manager and exposed to ambient for should report any temperature log for the
after ignored after have their own monitored of the hour. For driver a long time already, it malfunctioning of truck quality control manager
packaging packaging. If favorite chilling all the time, fridge all truck, is better discard all the or fridge. Otherwise, to review
left in conditions. it should be the time. should food since they might they should be
ambient Nonetheless, salad maintained Hire trucks monitor be spoiled already. responsible for the
during should generally be under 4°C with all the Ensure the truck and setting fridge so that the
storage and stored under 4°C to refrigeratio time fridge are maintained temperature can be
shipping, the maintain the cold n only. at low temperature maintained. Any
salad is very chain. next time. incidents should be
likely to noticed for future
spoil, review.
especially in
truck with
no
refrigeration

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