HACCP Certification for Supermarkets and Food Retailers
[edit] Introduction
Supermarkets and food retailers manage food safety across a wide range of activities. Products may arrive from suppliers, pass through receiving areas, enter chilled, frozen or ambient storage, move to display areas, and undergo cutting, preparation, cooking, cooling, repacking, sampling or other forms of handling before sale. Each stage can introduce or increase a food safety hazard if appropriate controls are not applied.
Hazard Analysis and Critical Control Point (HACCP) is a systematic approach to identifying food safety hazards and establishing controls at points where those hazards can be prevented, eliminated or reduced to acceptable levels. In retail environments, HACCP-based food safety management can bring together controls covering receiving, storage, preparation, temperature management, personal hygiene, cleaning, cross-contamination, pest control, traceability, corrective action and record keeping.
In the UK, food businesses are generally required to operate food safety management procedures based on HACCP principles. HACCP certification is different from this legal requirement. Certification normally refers to an independent assessment of a food safety system against a specified standard or certification scheme. There is no single universal HACCP certificate that all supermarkets are legally required to obtain. The value of certification therefore depends on the scope and criteria of the assessment and, most importantly, on whether the underlying food safety system is effectively implemented.
[edit] HACCP in supermarket and retail operations
A HACCP system should be developed around the actual activities undertaken by the food business rather than copied from another organisation. The scope may include receiving, storage, preparation, cooking, cooling, display, packaging and retail handling, depending on the operation.
The hazards and controls will vary considerably between retailers. A store selling only packaged, shelf-stable food has a different risk profile from a supermarket that includes a bakery, deli, butcher, fish counter, hot-food service or fresh produce preparation area. The HACCP system should therefore reflect the foods handled, intended use, equipment, premises, processes, storage conditions and working practices.
HACCP is based on seven principles: hazard analysis; determination of critical control points; establishment of critical limits; monitoring; corrective action; verification and review; and documentation and record keeping. These principles are supported by prerequisite programmes and good hygiene practices. Cleaning, maintenance, personal hygiene, pest control, waste management and suitable premises and equipment are examples of controls that normally provide the foundation for HACCP-based procedures.
A critical control point (CCP) is a step where control is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. Not every food safety check is a CCP. For example, some temperature, cleaning or receiving checks may form part of prerequisite or operational controls rather than being critical control points. The classification should be determined through hazard analysis of the particular process.
[edit] Identifying and controlling food safety hazards
[edit] Hazard identification
HACCP considers biological, chemical and physical hazards. Biological hazards include harmful bacteria, viruses, parasites and other microorganisms. Chemical hazards can include cleaning chemicals, contaminants, naturally occurring toxins and inappropriate substances entering food. Physical hazards include foreign materials that could contaminate food during handling or processing. Allergens also require specific controls because their unintended presence or incorrect declaration can create a serious food safety risk.
Retailers should consider where hazards can enter, increase, survive or be transferred throughout the operation. This requires consideration of the complete product flow rather than just the sales area. Receiving docks, storage rooms, preparation areas, equipment, staff practices, waste handling and customer-facing activities can all be relevant.
The assessment should consider the characteristics of the food, its intended use and the processes applied to it. Ready-to-eat foods require particular attention because they may receive little or no further processing before consumption.
[edit] Receiving and supplier controls
Food safety controls begin when products arrive at the premises. Receiving staff should understand the acceptance criteria applicable to different products. These may include packaging integrity, product condition, labelling, dates, temperature, evidence of contamination and other specified requirements.
Where a delivery does not meet the required criteria, the food should be rejected, held, segregated or otherwise controlled according to the food safety procedure. Employees should not make informal decisions that could allow potentially unsafe food to enter normal stock.
Supplier controls can also form part of the wider food safety management system. Retailers may need to establish appropriate requirements for suppliers, product specifications, transport conditions and information accompanying deliveries. Records can provide evidence of checks and support traceability when problems arise.
[edit] Temperature control
Temperature control is an important food safety measure for many chilled and frozen foods. The appropriate temperature requirements depend on the food, process and applicable legal or operational requirements. Retailers should establish suitable limits and monitoring methods for the products they handle rather than relying on a single temperature value for every situation.
Monitoring should cover the equipment and locations relevant to food safety. Employees should know how measurements are taken, what is recorded and what action is required when a result falls outside an established limit or requirement.
Operational events can affect temperature control. Deliveries, equipment failures, power interruptions, overloading of refrigerated displays and frequent opening of doors can all affect food temperatures. The HACCP-based system should consider foreseeable failures and establish appropriate responses.
[edit] Cross-contamination and food handling
Supermarkets commonly handle raw meat, poultry, fish, eggs, ready-to-eat foods, bakery products, fresh produce and packaged foods within the same premises. The movement of people, equipment and products can create opportunities for cross-contamination.
Controls can include suitable separation of raw and ready-to-eat foods, dedicated or appropriately controlled utensils and work surfaces, effective hand hygiene, controlled storage, appropriate cleaning and suitable product flows. Employees should understand the purpose of these controls and the action required when separation is compromised.
Particular attention is required where foods are cooked or otherwise subjected to a process intended to control microbiological hazards. Contamination after the control step can reintroduce hazards, particularly for foods that are subsequently handled or stored before sale.
[edit] Cleaning, hygiene and pest control
Cleaning and disinfection are important prerequisite controls within food safety management. Procedures should cover food-contact surfaces, equipment, floors, drains, storage areas, display equipment and other relevant locations. Cleaning chemicals should be stored and used in a manner that prevents contamination of food and food-contact surfaces.
Personal hygiene is also an essential control. Procedures should address hand washing, protective clothing where appropriate, illness reporting and other practices relevant to the activities undertaken.
Pest control should include measures to prevent access, identify evidence of infestation and respond to problems. Damaged packaging, pest activity, standing water, inadequate waste management and defects in the fabric of the premises can all contribute to pest risks.
Records can demonstrate that required procedures have been carried out, but documentation does not replace effective control. Supervisory checks and other verification activities should assess whether cleaning, hygiene and pest-control measures are actually working.
[edit] Monitoring, corrective action and traceability
Monitoring provides evidence that specified controls are operating as intended. Depending on the food safety system, this may include temperature measurements, receiving inspections, equipment checks, cleaning verification, observations of food handling and monitoring at identified critical control points.
Where a critical limit is not met, corrective action should be defined in advance. Depending on the circumstances, this may involve stopping or correcting a process, isolating affected food, assessing its safety, adjusting equipment, determining whether food can be released, documenting the incident and escalating the issue for further investigation.
Traceability is particularly important where products are received, repacked, prepared, combined or otherwise changed within the retail operation. Records should allow the business to identify relevant products and determine what action is necessary if a food safety problem is discovered.
Product identification and segregation procedures should prevent affected or suspect food from being inadvertently returned to sale. Where foods are repacked or prepared on the premises, the food safety system should also consider labelling, allergen information, shelf life and product identification.
[edit] Training and management responsibilities
A HACCP system is dependent on employees understanding and applying the controls relevant to their work. Receiving staff, food handlers, department managers, cleaners, maintenance personnel and supervisors may have different food safety responsibilities.
Training should relate to the actual activities carried out in the store. Practical scenarios can help employees understand how procedures apply when, for example, a chilled delivery arrives outside its acceptance criteria, a refrigeration unit records an abnormal temperature or raw food comes into contact with a surface used for ready-to-eat food.
Training should be reinforced through supervision and updated when processes, products, equipment or responsibilities change. Recurring errors and food safety incidents can also identify areas where additional instruction is required.
Management has responsibility for ensuring that food safety arrangements remain appropriate and adequately resourced. This includes providing suitable premises and equipment, maintaining prerequisite controls, allocating responsibilities, reviewing performance and ensuring that corrective actions are completed.
[edit] HACCP certification and assessment
HACCP certification normally involves an independent assessment of a defined food safety management system against specified requirements. The scope of an assessment should be clear because a certificate covering particular activities or premises does not necessarily demonstrate that every operation undertaken by a retailer has been assessed.
Preparation for certification should begin with a review of the actual food operation. The product flow should be examined from receiving through storage, preparation, display and sale, with hazards and control measures identified at each relevant stage. The HACCP team should include people with appropriate knowledge of the operation and food safety.
The system should contain sufficient evidence to demonstrate that the HACCP principles have been applied. Depending on the operation, this may include the scope of the study, product information, flow diagrams, hazard analysis, control measures, identification of CCPs, critical limits, monitoring arrangements, corrective actions, verification procedures and records.
Certification should not be regarded as proof that food is permanently safe or that an operation is free from food safety risks. An assessment represents a review against defined criteria at a particular time and within a particular scope. Continued food safety depends on the system being maintained and applied in everyday operations.
[edit] Reviewing and maintaining the HACCP system
HACCP systems should be reviewed when changes could affect food safety. Changes to products, suppliers, processes, equipment, store layouts, preparation activities or storage arrangements may require the hazard analysis and control measures to be reconsidered. Reviews may also be prompted by incidents, emerging hazards, inspection findings or recurring deviations.
Verification should provide evidence that the system is working as intended. This can include review of monitoring records, observation of working practices, calibration of measuring equipment, inspection of premises and equipment, review of corrective actions and analysis of trends.
Trend analysis can reveal problems that are not apparent from individual records. Repeated temperature deviations at a particular display, for example, may indicate an underlying equipment, loading or maintenance problem. Similarly, recurring cleaning failures may indicate weaknesses in equipment design, procedures, staffing or training.
Management review can bring this information together and determine whether changes are needed to equipment, procedures, staffing, training or other aspects of the operation. The objective is continuous control of food safety hazards rather than preparation for a single certification assessment.
[edit] Making HACCP practical in retail environments
Supermarkets operate under changing and sometimes demanding conditions. Deliveries, replenishment, customer service, equipment failures and prepared-food activities can all place pressure on food safety controls. Procedures therefore need to be sufficiently clear and practical to be followed during normal and abnormal operating conditions.
Responsibilities should be defined so that employees know who performs checks, who reviews records, who controls non-conforming food and who should be notified when an incident requires further investigation. Clear procedures reduce the likelihood of inconsistent decisions during busy periods.
Digital monitoring and record-keeping systems can assist where they provide reliable measurements and appropriate records. They do not, however, replace the need for competent employees, effective procedures, verification and management oversight.
The effectiveness of HACCP in retail ultimately depends on how well the system is integrated into everyday work. Regular checks, appropriate temperature control, effective cleaning, prevention of cross-contamination, correct handling of food, traceability, timely corrective action and accurate records should operate as parts of a coherent food safety management system.
[edit] Related articles on Designing Buildings
Featured articles
Check out some of the best features and news from Designing Buildings as well as key stories from around the web.
The importance of early engagement
Construction lessons from the Trillium HealthWorks Experience Centre.
Mayors are to be given planning call in powers
Mayors across England will be able to make the most important planning decisions.
The Master Builder: William Butterfield and his times. Book review.
Why construction can't afford to ignore the skills gap.
Building Safety Regulator, 19 August
Gill Kernick appointed Independent Chair of Residents’ Panel.
Connecting knowledge, technology and conservation
Building competence for the future of built heritage.
Building Regulations and Building Safety Act
CIOB publishes free advice for non-domestic clients.
Building Safety Newsletter from MHCLG.
An extraordinary record of steel engineering worldwide.
Households living near new pylons to save on bills.
ECA warns growth must not outpace grid capacity or skills.
The role of the client and decision making
CIOB response to built environment professions call for evidence.

















