After identifying potential hazards in your food process, the next crucial step in HACCP implementation is determining exactly where those hazards can be controlled. Principle 2 focuses on identifying Critical Control Points (CCPs) - specific steps where control measures must be applied to prevent, eliminate or reduce food safety hazards to acceptable levels.
A Critical Control Point is defined as "a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level”. The correct identification of CCPs is vital for effective food safety management, as these points become the primary defense against potential hazards reaching consumers.
Using a CCP decision tree
Determining whether a process step qualifies as a CCP involves careful analysis and judgment. One of the most effective tools for this purpose is a CCP decision tree - a systematic flowchart that guides you through a series of questions to identify CCPs. Although helpful, a decision tree is merely a tool and not a substitute for expert knowledge.
Several decision tree models exist, with the most common being:
- Codex Decision Tree - Recently revised in 2023 by the Codex Alimentarius Commission, this model typically identifies more CCPs and involves answering four key questions:
- Can the significant hazard be controlled by prerequisite programs?
- Do specific control measures for the identified significant hazard exist at this step?
- Will a subsequent step prevent, eliminate or reduce the hazard to an acceptable level?
- Can this step specifically prevent, eliminate or reduce the hazard to an acceptable level?
- Campden BRI Decision Tree - This alternative model generally produces fewer CCPs than the Codex tree because it doesn't identify steps where hazards are effectively controlled by prerequisite programs as CCPs.
When using any decision tree, you should document your reasoning for each answer and keep records of the decision process. Moreover, if in doubt about an answer to any question, it's prudent to assume the worst situation until you have evidence otherwise.
Examples of CCPs in food processing
CCPs vary widely depending on the nature of the food product, processing methods, equipment, plant layout, and other factors. Common examples of CCPs in food processing include:
- Thermal processing (cooking, pasteurization) - Controls biological hazards by destroying pathogens
- Chilling/refrigeration - Prevents microbial growth in high-risk foods
- Metal detection - Identifies and removes physical contaminants
- pH adjustment - controls microbial growth
- Formulation control - Ensures proper composition to inhibit hazards
- Sifting - Removes physical contaminants
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Additional practical examples of CCPs in food processing
| Industry | Process Step (CCP) | Hazard Controlled | Control Measure |
|
Catering / Hospital Meals |
Final cooking step for chicken | Biological (Salmonella) | Cooking to ≥75°C internal/ core temperature and verifying with calibrated probe |
| Bottled Water Plant | UV sterilization post-filtration | Biological/ (Pathogens in water) | UV intensity control and lamp replacement schedule |
| Bakery with allergen products | Product changeover cleaning |
Chemical (Allergen cross-contact) | Validated allergen cleaning protocols and swab testing |
| Juice bottling plant | Metal detection post-filling | Physical (Metal shards) | In-line metal detector with automatic rejection and daily sensitivity verification |
| Infant formula factory | Dry blending of powdered ingredients | Chemical (Incorrect vitamins levels) |
Formulation control via recipe management software and batch testing |
| Dairy plant | Pasteurization of milk | Biological (Listeria, E. coli) |
Time-temperature monitoring of pasteurization |
| Date packaging center | Final visual inspection line | Physical (Stones, stems) | Manual inspection + mechanical sifting system |
| Canned food production | Retort heat treatment (sterilization) | Biological (Clostridium botulinum) | Retort temperature/pressure recording and validation study |
| Ready-to-eat salad factory | Washing with sanitizing solution | Biological (E. coli, Norovirus) | Free chlorine concentration monitoring and contact time verification |
For instance, in dairy processing, pasteurization serves as a CCP to eliminate pathogens like Listeria and Salmonella. Likewise, in meat processing, cooking to a specific internal temperature acts as a CCP to destroy harmful bacteria.
Field example:
A Dubai-based hummus manufacturer identified metal detection after filling and sealing as a CCP because small pieces of worn mixer blades had previously entered product. Installation of a calibrated metal detector at the final line significantly reduced complaints and product returns.
A Saudi bakery producing gluten-free products treats allergen control during packing as a CCP due to the high risk of gluten cross-contact, especially when switching between production of standard and gluten-free items. A documented swab test and label check protocol was implemented.
The location of CCPs will differ between facilities even when producing similar food items due to variations in facility layout, equipment, ingredient selection and processes employed. Consequently, each food operation must identify its own unique set of CCPs based on its specific conditions.
Difference between CP and CCP
Understanding the distinction between a Control Point (CP) and a Critical Control Point (CCP) is fundamental to implementing an effective HACCP plan:
Control Point (CP) is any step where biological, chemical or physical factors can be controlled. While important for overall quality and safety, CPs are not absolutely critical - either because the risk is low or because a mistake at this point is unlikely to result in unsafe food.
Critical Control Point (CCP) is a step that is absolutely necessary to control a reasonably likely food safety hazard. At these points, failure to maintain control would likely result in an unacceptable health risk.
The primary differences include:
- Criticality: A CCP is essential for ensuring food safety, whereas a CP is important but not crucial.
- Consequence of failure: Failure at a CCP likely results in unsafe food reaching consumers; failure at a CP typically affects quality rather than safety.
- Monitoring requirements: CCPs require more rigorous, documented monitoring procedures compared to CPs.
- Corrective action: When a CCP is out of control, specific corrective actions must be taken and documented.
To illustrate, consider cooking chicken: The cooking step is a CCP because it's necessary to destroy Salmonella (a likely hazard). In contrast, checking employee handwashing throughout the day might be a CP - helpful but not the last or only defense against contamination.
Practical examples: CCP vs. CP in food processing
| Process Step | Hazard Type | CCP or CP? | Explanation |
| Cooking chicken in a central kitchen | Biological (Salmonella) | CCP | Must reach ≥75°C core temperature to destroy pathogens; failure = unsafe food. |
| Employee handwashing at start of shift | Biological (cross-contamination) | CP | Important for hygiene, but not the last point of control - reinforced by PRPs. |
| Metal detection after packaging of snacks | Physical (metal fragments) | CCP | Final step to detect and reject contaminated product before it reaches the customer. |
| Cooling of cooked rice in a catering kitchen | Biological (Bacillus cereus) | CCP | Improper cooling can lead to spore germination; must reach ≤5°C within 2 hours. |
| Pest control inspection around facility | Biological (pest-borne contamination) | CP | Preventive action via PRP - failure doesn’t directly lead to unsafe product if managed elsewhere. |
| Packaging integrity check for bottled milk | Physical/ Biological (leakage contamination) | CCP | Broken seals can allow pathogen entry, and they must be monitored and controlled. |
| Storage of cleaning chemicals in separate area |
Chemical contamination |
CP | Prevents accidental contamination, but food contact is unlikely if procedures are followed |
| Floor cleaning in processing hall |
Biological/ Physical |
CP | Important for hygiene and pest control but not directly related to food contact or hazard control. |
Ultimately, the distinction lies in whether the control at that point is the last opportunity to address a significant hazard before the food reaches consumers. Thus, proper identification of CCPs forms the backbone of your entire HACCP system and ensures your food safety efforts are focused where they matter most.
Quick summary tip
CCP = Last line of defense. If this fails, food safety is at risk.
CP = Important, but not critical
- Supports hygiene, quality, or accuracy
- Does not directly prevent or eliminate a significant food safety hazard
- Often included in PRP (Prerequisite Program) or GMP (Good Manufacturing Practices)
Read more about Understanding HACCP Principle 1: Conduct a Hazard Analysis.
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