Designing, developing, and maintaining robust Hazard Analysis and Critical Control Points (HACCP) plans is vital to safely and consistently manufacturing high-quality foods, beverages, and dairy products such as infant formula and powders.

When you decide to work with Produco, our team take a hands-on approach to understanding your business and how it operates throughout the entire procurement, supply chain, manufacturing, laboratory, testing, distribution and end-customer process. 

Reviewing your HACCP plans regularly is necessary. Changes occur frequently in manufacturing facilities, so HACCP plans need to capture the processes that actually take place in the plant are recorded accurately and verified. This ensures your products are safe for customers, consumers and that your systems are working efficiently.

Creating a procedure that triggers when your HACCP plan should be reviewed is the first step to ongoing success.  A well-reviewed HACCP plan assures high-quality products and helps to safeguard the reputation of your company and brand.

Our experience in end-to-end supply chain environments will provide you with new opportunities to strengthen your food business and improve quality and overall performance.

Produco can improve your overall food safety by identifying how a traceability system informs your overall HACCP system.  A traceability system provides a set of information about the location of food and food ingredients along the supply chain. 

We recommend an external review of your HACCP plans at least once a year.  This helps to:

• Assure all process steps are completed and documented accurately
• Satisfy regulatory requirements such as FSANZ
• Be better prepared for external audits

Employing an external food safety consultant provides your business with a fresh perspective and can identify important issues or process gaps.

This practice may assist your company in preventing a foodborne illness outbreak, a major recall or regulatory non-conformances. All of which can be costly to your business and brand reputation.

The reviews offered by us can include part, or all of the following steps:

1). Documentation Reviews

• We provide a complete review of all existing written HACCP plans, SOP’s and PRP’s to ensure they meet the current regulatory requirements.
• We analyse Process Flow Charts, checking the correlation with Hazard Analysis and vice versa, and ensuring additional inputs such as Rework and Returned Product are captured.

Dependent on your business, this can be performed in the plant and/or remotely.

2). Plant Audit

Process Flow Chart and Critical Control Point (CCP) Verification – a physical examination/walk-through of the production area with management and staff to review and refine processes:

• Audit of CCP monitoring
• CCP verification requirements

3). Records Review

• Critical reviews include CCP’s, Standard Operating Procedures (SOP’s), Corrective Actions, Microbiological test results of food product plus surface and environmental testing results as part of the Validation process to ensure hazards are being effectively controlled.

4). Decision Making

• Development of decision-making documents to capture and record how potential hazards, CCP’s, critical limits and target limits were identified.
• Relevant regulatory supporting documentation is included in these documents for validation purposes.

 5). Reassessment Documentation

• Tailored to your specific improvement goals.
• A full reassessment report including records of the processes and subsequent changes will be collated. Includes in-plant evaluation data and checklists, including CCP’s and Critical limits.