Ensuring food safety is a top priority in the food industry. The Hazard Analysis and Critical Control Points (HACCP) system plays a crucial role in controlling potential hazards and ensuring consumer safety. An essential part of HACCP is identifying Critical Control Points (CCPs). So, what exactly are CCPs? What are the 4 types of CCP decision trees? In this article, let’s discuss in detail these common types of CCP decision trees with GOL and provide guidance on how to use them to effectively identify CCPs.

What is a Critical Control Point (CCP)?

According to the FDA’s definition, a Critical Control Point (CCP) refers to any step in a process where control measures can be applied to prevent or eliminate potential food safety hazards. Emphasizing a systematic approach, significant attention is placed on critical control points throughout the food production process. Failure to maintain control over established parameters at these points can lead to adverse public health consequences due to unsafe food.

Identifying potential food hazards in each step is a fundamental prerequisite for designating critical control points, based on the seven Hazard Analysis and Critical Control Points (HACCP) principles. Food handlers are obligated to address all foreseeable hazards that could cause illness or injury if left uncontrolled, including microbiological contamination, chemical contamination, or the presence of foreign matter.

Examples of critical control points may encompass:

• Thermal processing
• Cooling procedures
• Chemical testing
• Biological hazard detection
• Formulation control
• Physical hazard testing

Thorough development and documentation of all critical control points are essential. Accurately established critical control points serve as the cornerstone for managing food safety hazards and are a fundamental component of HACCP food safety programs.

A critical control point, if overlooked, skipped, or inadequately addressed, can potentially lead to legal repercussions due to food safety concerns. While end-product testing is not considered a critical control point, as little can be done once the food product has undergone processing, critical control points serve as crucial control measures tailored to the unique characteristics of each food manufacturing business, the types of products produced, and the raw materials utilized.

For instance, ensuring the safety of chicken involves cooking it to an internal temperature of approximately 165°F (75°C), whereas beef requires a lower temperature of around 145°F (60°C-65°C) for roasting. Conversely, businesses handling fresh produce like vegetables may prioritize critical control points such as chemical testing for pesticide residue or microbial toxin presence.

How to Identify Critical Control Points

To pinpoint the critical control points within your food business, the initial step is to identify all potential food safety hazards that could reasonably occur. These hazards are typically categorized as biological, chemical, or physical, although a single agent may pose multiple hazards. For instance, hair found in soup constitutes both a physical hazard and a biological hazard due to the presence of bacteria and other microorganisms on the hair.

Visualizing the flow of food and ingredients throughout your business can aid in hazard identification and critical control point determination. Consider a scenario where your establishment is a full-service restaurant specializing in grilled chicken sandwiches, one of your popular menu items. Deconstructing the sandwich into its constituent ingredients and mapping out the journey of each ingredient from procurement to serving can be insightful. This journey typically involves:

• Purchasing
• Receiving
• Storing
• Preparation
• Cooking
• Plating
• Serving

At each of these stages, you or your Food Handlers perform vital tasks crucial for ensuring food safety. For instance, in the case of a grilled chicken sandwich, critical tasks may include:

• Storing raw chicken in a refrigerator at a temperature of 5°C or below to inhibit bacterial growth.
• Cooking chicken to a minimum internal temperature of 75°C to eradicate bacteria.

In essence, a critical control point denotes a task that must be executed to prevent, mitigate, or eliminate a food safety hazard. Tasks related to dish preparation that are not integral to safety, such as garnishing or visual presentation, do not qualify as critical control points. If skipping a step does not pose a risk of harm or illness, it is likely not a critical control point.

4 types of CCP decision trees

There isn’t a universally agreed-upon set of four CCP decision trees. Different organizations and regulatory bodies may have their own variations. However, some of the most common CCP decision trees you’ll encounter include:

• Codex Decision Tree: Developed by the Codex Alimentarius Commission, an international body focused on food safety standards. This tree is known for being relatively strict and identifying more CCPs.
• Campden BRI Decision Tree: Developed by the Campden BRI (Campden Beverages Research Institute) in the UK. This tree takes a more holistic approach, considering existing prerequisite programs alongside the specific step to determine if it qualifies as a CCP. It tends to identify fewer CCPs than the Codex tree.
• FDA Decision Tree: While the US Food and Drug Administration (FDA) doesn’t have a single, official decision tree, some resources reference a tree similar to the Codex version.
• ISO 22000 Decision Tree: Based on the ISO 22000 standard for food safety management systems, this tree emphasizes the importance of preventive controls throughout the process and may identify CCPs based on the severity and likelihood of hazards.

It’s important to note that these decision trees are just tools to guide you, not a rigid set of rules. The specific CCPs for your process will depend on the unique nature of your product and operation.

What Are Control Measures?

Control measures refer to actions or activities designed to mitigate or eliminate an identified potential hazard, or to reduce its likelihood of occurrence to an acceptable level. Essentially, control measures encompass any intervention, step, task, process, or procedure aimed at addressing a food safety hazard. The term “control measure” is utilized because while not all hazards can be entirely prevented, they can be effectively managed.

It’s important to note that control measures are not necessarily synonymous with critical control points. They can range from simple steps such as maintaining proper hygiene, conducting adequate testing, adhering to sanitation routines, implementing pest control measures, to providing regular training.

Understanding control measures in the context of food preparation involves categorizing them based on their nature, their relationship to the process, and the level of risk to consumers in the event of a control measure failure.

Examples of control measures include:

• Control Points (CP)
• Critical Control Point (CCP)
• Prerequisite Programs (PRP)
• Operational Prerequisite Programs (oPRP)
• Quality Control Points (QCP)

The responsibility for ensuring food safety is paramount in maintaining a positive reputation in the food industry. This responsibility entails identifying hazards, establishing and monitoring critical control points, and implementing verification steps to ensure food safety control. These meticulous steps, from ingredient procurement to plating the final dish, play a pivotal role in minimizing health hazards and fostering customer loyalty to your establishment.

What are the differences between CP, CCP, PRP, and oPRP?

When crafting a comprehensive HACCP food safety plan, it’s essential to grasp the nuances of various terminologies such as control point (CP), critical control point (CCP), prerequisite program (PRP), and operational prerequisite program (oPRP). Let’s delve into each of these terms to gain a deeper understanding of their roles in ensuring food safety:

Control Point (CP): A control point signifies any step within the food production process where biological, chemical, or physical hazards can be managed. While CPs may not always be critical in completely eliminating hazards, they play a crucial role in preventing and reducing risks. For instance, a control point could involve pre washing potatoes before blanching, thereby addressing physical hazards before proceeding with further processing. CPs are integral to the Hazard Analysis and Risk-Based Preventive Controls (HARPC) food safety system.

Critical Control Point (CCP): As a fundamental tenet of HACCP principles, a CCP represents a step in the production process where control measures are essential for preventing or eliminating food safety hazards, or reducing them to an acceptable level. Unlike control points, CCPs are the final checkpoints where hazardous contaminants can be effectively mitigated. The identification and management of CCPs are pivotal in ensuring the safety and quality of food products.

Prerequisite Program (PRP): PRPs encompass essential conditions and activities that are vital for maintaining a hygienic environment throughout the food chain. These programs establish the foundational framework necessary for controlling low to moderate-risk levels. Examples of PRPs include implementing robust employee hygiene practices, adhering to stringent hand washing protocols, implementing pest control measures, and ensuring basic sanitary design principles. PRPs serve as the cornerstone of a HACCP food safety plan, laying the groundwork for effective hazard control and prevention.

Operational Prerequisite Program (oPRP): An oPRP encompasses specific operational activities and measures that are crucial for supporting PRPs and ensuring the overall effectiveness of a food safety management system. These operational activities are essential for controlling food safety hazards and maintaining compliance with regulatory requirements. While PRPs establish the foundational framework, oPRPs provide the operational procedures and protocols necessary for implementing and monitoring food safety measures effectively.

In summary, understanding the distinctions between CPs, CCPs, PRPs, and oPRPs is essential for developing a robust HACCP food safety plan. By delineating the roles and responsibilities associated with each term, food businesses can effectively identify, assess, and mitigate food safety hazards, thereby ensuring the safety and integrity of their products throughout the production process.

Common prerequisite programs might encompass:

• Sanitation Standard Operating Procedure (SSOP)
• Compliance with current Good Manufacturing Practices (cGMP)
• Building construction and layout
• Premises arrangement
• Management of air, water, and energy supplies
• Receiving and storage procedures for goods
• Maintenance of production equipment
• Measures aimed at preventing cross-contamination
• Pest management protocols
• Systems for traceability and recall
• Staff hygiene practices
• Cleaning and sanitation procedures

Operational prerequisite program (oPRP): Intermediate measures and actions implemented to mitigate the likelihood of encountering high levels of identified risks during the manufacturing process. The utilization of oPRPs is contingent upon food safety regulations and can vary between different jurisdictions. These programs are not generic steps; rather, they are tailored to address specific hazards identified through thorough hazard analysis

Critical Control Points (CCPs) in the food industry

Here are several critical control points commonly found in the food industry, along with their underlying principles:

• Cold Storage: Cold storage serves as a critical control point for various reasons, especially when dealing with raw meat. The principle behind cold storage is to slow down or halt biological processes by maintaining low temperatures. This prevents the growth and multiplication of microorganisms, thereby preserving the quality of food and preventing the occurrence of foodborne illnesses. Refrigerating precooked foods also helps to inhibit the growth of hazardous microorganisms.
• Thermal Processing: Thermal processing refers to heat treatments designed to eliminate specific pathogens from food products. Processes such as canning, baking, and pasteurization are examples of thermal processing methods. The critical control point lies in ensuring that the time and temperature parameters are sufficient to destroy harmful microorganisms without compromising the quality of the food. Failure to adhere to these parameters can result in food safety issues, as certain pathogens may survive and pose health risks to consumers.
• Hot Storage/Displaying Hot Food: Keeping finished products, such as precooked meals, at temperatures of 140°F (60°C) or above is crucial to prevent bacterial growth while the food is displayed or stored. This practice ensures that the food remains outside the temperature danger zone (40°F to 140°F or 5°C to 60°C), where pathogens thrive. Failure to maintain proper temperatures can lead to foodborne illnesses and pose risks to consumer health.
• Cooling/Preparing Cooked Foods: Promptly cooling cooked foods and storing them at appropriate temperatures is essential to prevent bacterial growth. Rapid cooling helps minimize the time during which microorganisms can multiply, reducing the risk of foodborne illnesses. Adhering to specific cooling standards within the first few hours of cooking ensures that food is safely preserved and maintains its quality. Similarly, proper thawing techniques are crucial to prevent the proliferation of surviving microorganisms during the thawing process.

Additional critical control points (CCPs) in the food industry include:

• Toxin Testing: Toxin testing serves as a critical control point for high-risk products such as peanuts, corn, and grains, which are prone to contamination by compounds like Aflatoxin. Aflatoxin is a regulated toxin produced by microorganisms and poses significant health risks to humans and animals. Detection of Aflatoxin during the receiving process is crucial to prevent contaminated raw materials from entering the production line. Failure to detect unacceptable levels of toxins can result in safety breaches, consumer complaints, health hazards, and legal issues. Rigorous inspection and testing protocols are implemented to ensure that raw materials meet safety standards before being accepted for use.
• Filth Detection Process: Filth detection is a general critical control point aimed at monitoring, detecting, and controlling physical hazards in food processing facilities. Various methods, including visual inspections, sieving, and the use of metal detectors, are employed to identify physical contaminants such as glass, metal fragments, jewelry, and other foreign objects. Failure to detect and remove these contaminants can lead to consumer injuries and compromise food safety. The size and type of contaminants are important factors in assessing their risk level and potential impact on product quality.
• Product Formulation Control: Product formulation control involves verifying the correct amounts of ingredients and raw materials used in food production. Pre-weighed ingredients are provided to production staff, and adherence to specified quantities is crucial to ensure product safety and quality. Deviations from prescribed formulations, such as insufficient preservatives or acidulants, can result in health hazards and microbial proliferation, compromising food safety. Proper monitoring and control of ingredient quantities help mitigate risks and maintain product integrity.

Identifying and implementing critical control points requires thorough hazard analysis and specialized expertise in food safety. Inexperienced teams may overlook important control points, necessitating the assistance of food safety consultants, albeit at a significant cost.

Why do we need to identify CCPs?

There are two main reasons why we need to identify CCPs (Critical Control Points)  in any process, especially those related to food safety:

1. Preventative Measures: CCPs are like guardrails on a road. They are the points in a process where we can intervene and prevent hazards from occurring, or at least reduce them to a safe level. By focusing on controlling these critical points, we can ensure the final product is safe for consumption.
2. Effective Resource Allocation: Not every step in a process is equally important for safety. Identifying CCPs helps us prioritize our resources. We can focus on implementing stricter monitoring and control procedures at these critical points, rather than spreading ourselves thin across the entire process.

We hope that the article has provided you with useful information about Critical Control Points (CCPs) in the food industry. If you are interested in these issues, please continue to follow our new articles to update more detailed information. If you have any questions, feel free to contact GOL. We are always ready to support and answer any questions you may have.

References: 

According to An official website of the United States government – U.S. Food & Drug Administration (FDA) – HACCP Principles & Application Guidelines

According to Wikipedia – Critical control point

Read more: 

https://golsolution.com/what-is-ultra-processed-food/