HACCP Plan Development: A Step-by-Step Guide for NSW Food Businesses

HACCP Plan Development for NSW Food Businesses

This guide provides a comprehensive walkthrough of developing a HACCP plan for a food business in NSW, following the Codex Alimentarius HACCP framework and aligned with Standard 3.2.1 of the Food Standards Code.

The 5 Preliminary Steps

Before applying the 7 HACCP principles, complete these foundational steps:

• 1. Assemble the HACCP team — people with knowledge of ingredients, processes, equipment, and food safety science
• 2. Describe the product — full description including composition, processing method, packaging, shelf life, storage conditions, and intended use
• 3. Identify intended use — who will eat the food? Does it include vulnerable populations (elderly, children, immunocompromised)?
• 4. Construct a flow diagram — a sequential diagram of every step from receiving ingredients through to consumption
• 5. Verify the flow diagram on-site — walk the process and confirm the diagram reflects what actually happens, not just what you think happens

Applying the 7 HACCP Principles

Principle 1 — Hazard Analysis: For each process step, identify and evaluate biological, chemical, and physical hazards. Assess significance based on likelihood and severity. Focus on hazards that are reasonably likely to occur.

Principle 2 — Identify CCPs: Apply the decision tree to each significant hazard. A CCP is a step where control is essential — missing it or losing control would result in an unacceptable risk.

Principle 3 — Critical Limits: Assign a measurable, science-based critical limit to each CCP. Use validated temperature/time combinations from Codex, FSANZ, or peer-reviewed sources.

Principle 4 — Monitoring: Define the monitoring procedure: what is measured, how, by whom, and how often. Continuous monitoring (e.g. cooking equipment thermostats) is preferred where possible.

Principle 5 — Corrective Actions: Write specific corrective actions for each CCP that address both the affected product and the root cause of the deviation.

Principle 6 — Verification: Establish activities that confirm your HACCP system is working. This includes internal audits, thermometer calibration, and review of monitoring records.

Principle 7 — Record Keeping: Maintain all HACCP records for a minimum of 3 months (best practice: 12 months). Records must be legible, dated, and signed.