Hazard Analysis Critical Control Points (HACCP) Course

Lesson 1 • History and Evolution of HACCP

Traces HACCP from NASA space-food origins to global regulatory adoption. Contextualises why the system is science-based and preventive rather than reactive.

Lesson 2 • Food Safety Hazard Categories

Defines biological, chemical, and physical hazards with real-world examples. Provides the hazard vocabulary used throughout all subsequent HACCP analysis steps.

Lesson 3 • Prerequisite Programs Overview

Identifies the foundational hygiene and operational programmes that must exist before HACCP is applied. Shows how PRPs reduce hazard load entering the HACCP system.

Lesson 1 • Process Scope and Boundaries

Defines the start and end points of the HACCP plan within the operation. Clear boundaries prevent overlapping or missing coverage across multiple plans.

Lesson 2 • HACCP Team Composition

Identifies the disciplines and expertise needed on an effective HACCP team. Establishes that multidisciplinary input is essential for complete hazard identification.

Lesson 3 • Team Meetings and Documentation Practices

Establishes structured meeting protocols and record-keeping habits for the HACCP team. Consistent documentation supports auditability and plan maintenance.

Lesson 1 • Mapping Inputs and Process Steps

Identifies all raw materials, packaging, water, and utilities entering each process step. Complete input mapping is prerequisite to identifying contamination entry points.

Lesson 2 • Principles of Flow Diagram Design

Teaches standard symbols, layout conventions, and level of detail required in HACCP flow diagrams. A well-designed diagram ensures no process step is overlooked during analysis.

Lesson 3 • On-Site Flow Diagram Verification

Describes the walkthrough method for confirming the diagram matches actual production. Discrepancies found during verification must be corrected before hazard analysis proceeds.

Lesson 1 • Hazard Evaluation: Severity and Likelihood

Teaches the two-dimensional risk matrix approach to evaluate each identified hazard. Evaluation determines which hazards are significant and require a control measure.

Lesson 2 • Hazard Identification Methods

Applies structured brainstorming, historical data, and scientific literature to list all potential hazards at each step. Comprehensive identification prevents gaps that could lead to unsafe products.

Lesson 3 • Completing the Hazard Analysis Worksheet

Guides students through populating a standardised hazard analysis table with all required fields. A complete, justified worksheet is the primary evidence of a science-based HACCP plan.

Lesson 1 • CCP Numbering and Plan Integration

Establishes a consistent CCP numbering system and links each CCP back to the hazard analysis. Proper integration ensures traceability from hazard to control throughout the HACCP plan.

Lesson 2 • Common CCPs in Food Processing

Reviews frequently identified CCPs such as thermal processing, metal detection, and pH control. Familiarity with common CCPs accelerates analysis and supports benchmarking.

Lesson 3 • The CCP Decision Tree

Walks through each question of the Codex decision tree with worked examples. Consistent application of the tree prevents both over-identification and under-identification of CCPs.

Lesson 1 • Designing CCP Monitoring Systems

Covers monitoring method selection, frequency, and responsible personnel for each CCP. Effective monitoring provides real-time assurance that critical limits are being met.

Lesson 2 • CCP Control Chart Completion

Guides students through assembling all CCP elements into a single control chart document. A complete control chart is the operational core of the HACCP plan.

Lesson 3 • Corrective Action Procedures

Establishes the steps taken when monitoring indicates a critical limit deviation. Corrective actions must address both the affected product and the root cause of the deviation.

Lesson 4 • Establishing Critical Limits

Defines critical limits using validated scientific data, regulatory standards, and process capability. Limits must be measurable, achievable, and sufficient to control the target hazard.

Lesson 1 • Verification Activities and Scheduling

Covers the range of verification activities including record review, CCP audits, and end-product testing. A scheduled verification programme provides ongoing confidence in plan effectiveness.

Lesson 2 • HACCP Record-Keeping Requirements

Defines the records that must be maintained, their retention periods, and access requirements. Complete records demonstrate due diligence and support regulatory inspections.

Lesson 3 • Validation of the HACCP Plan

Confirms that the combination of control measures, critical limits, and monitoring is scientifically sufficient to control identified hazards. Validation is completed before full implementation.

Lesson 1 • Key Performance Indicators for HACCP

Defines measurable KPIs that track HACCP system health, including CCP compliance rates and corrective action closure times. KPIs enable data-driven management review and improvement.

Lesson 2 • Preparing for External HACCP Audits

Equips students to organise documentation, brief staff, and respond to auditor findings professionally. Audit readiness demonstrates system maturity and supports certification maintenance.

Lesson 3 • Continuous Improvement Methodologies

Applies root cause analysis, PDCA cycles, and trend data to drive ongoing HACCP system improvement. Continuous improvement transforms HACCP from a static document into a living system.

Lesson 4 • Implementation Planning and Rollout

Develops a phased implementation plan including training, resource allocation, and go-live milestones. Structured rollout minimises disruption and ensures staff readiness before launch.