HACCP Program for Warehouse Handling Food Products- A simple Guide for Startups

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Definitions of terms used . Before we get started, let's first look at key terms to be used in this blog. Hazard Analysis Critical Control Point (HACCP) HACCP is a food safety management system that addresses food safety concerns through the analysis and control of contaminants (physical, chemical, and biological). Critical Control Points (CCP) Step in the process at which a control measure is applied to prevent or reduce a significant food safety hazard to an acceptable level. Critical limits Measurable values that separate acceptability from unacceptability. Deviation Non-fulfillment of a set requirement. Corrective actions These are actions  taken to eliminate a deviation and to prevent its recurrence. Risks Risks are the effects or consequences of the uncertainty of an event. Setting up a HACCP Program for Warehouse The food chain starts from the garden and ends at the consumer’s table. Along this chain, there are several players involved, and among these are warehouses or food
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Receiving procedure for Food Warehouses

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Keywords

Certificate of conformity

A document issued by a supplier showing that the supplied products meet a specific criterion

Non-conforming record

A form in which details of products that don’t conform to quality standards are recorded for traceability.

Non-conforming area

A designated place in the storage area in which non-conforming goods are separated from the rest of the products while awaiting final disposition.

Receiving Procedure

     It is perhaps the most important of all warehouse activities. If done wrong, it doesn't matter how well-handled other activities are - the output will be non-conforming products. To explain this better, I will borrow a computing phrase "garbage in, garbage out."

 There are several quality checks carried out at the receiving stage, and these include; delivery truck inspection, food product inspection, and receiving area inspection. Remember, all these quality inspections target possible hazards identified during the hazard analysis in the HACCP Program.

The delivery truck inspection;

   Inspect the seal integrity for any form of tampering because it is proof that the product has not been tampered with during transportation, and it is safe from any form of sabotage. 

     A designated receiving personnel inspects the delivery truck for general cleanliness: looking out for visible dirt, pests, offensive odors, and any other possible contaminants that could pose a risk to the food product. In the case of temperature-sensitive products (chilled and frozen products), the delivery truck temperature is checked as well (from the temperature readout) for conformity to the set receiving standard as laid out in the HACCP program. 

The product inspection

Temperature-sensitive products

         The product temperature is measured using a clean and sanitized calibrated thermometer. I advise using a probe thermometer as opposed to the infra-red thermometer. The reason is simple- Infra-red thermometer only measures surface temperature, yet the probe thermometer measures the product's internal temperature, which gives a better understanding of the temperature status of the products. However, when using a probe thermometer, care should be taken not to pierce a product packaging as this can be a source of contamination. The probe is placed between two primary packages when taking the product temperature.

         For a representative temperature status of the product, the readings are taken repetitively during offloading. For a better insight into the temperature of a particular product, pick samples from the front, middle, and back of the product compartment. 

For delivery trucks with temperature monitoring devices, the data is downloaded and checked to see if the product has been in a specified temperature range during transportation.

         Inspect the product cartons for sufficient expiry date, proper labeling, and any damage sustained during transportation. Damaged goods are non-conformed or put on hold for further inspections by designated quality personnel.

A properly labeled product conforms to the following;

  • Ingredients contained in the product.
  • Health risks associated with the product.
  • Storage instructions.
  • Use by date (expiry date).

Note; These are not standard requirements for a product label, they can change depending on regulatory, statutory laws, or client's needs.

     The products must have an accompanying Certificate of Conformance (COC) or Certificate of Analysis (COA) from the supplier. This certification is evidence that the supplier followed all the statutory and regulatory rules during the production of the product. 

If the food product deviates from any of the above criteria, it is labeled as a non-conforming product and transferred to a designated storage area that meets its storage instructions - Put chilled products in the chiller's non-conforming area, and frozen non-conforming products into the non-conforming area in a freezer. Record all non-conforming product details in a non-conforming form.

Please note: 

  • The product should not have signs of prior temperature abuse or signs of thawing and refreezing such as big ice crystals in or on the product.
  • The product temperature range is given by a regulatory body, a statutory body, or a client. But generally-chilling products are kept at 1°C-4°C and frozen products at -18°C (max < -12° C).

To know more about how to calibrate thermometer, check out this useful resource; how-use-and-calibrate-probe-thermometer.

Dry products and packaging material

Just like temperature-sensitive products, a dry product consignment must have a certificate of analysis or certificate of conformance. Check the dry products for sufficient expiry, damaged goods, proper labeling, and other contaminants that could make the product unsafe for consumption. Record all product details in the receiving form, and for the non-conforming products, their details are recorded in the non-conforming record.

Receiving area

In the case of temperature-sensitive products, the receiving activities are carried out in a temperature control dock maintained at 1°C-7°C for not over one hour, but the warehouse management can choose a stricter temperature and time range. 

Receiving personnel

     Designated receiving personnel must be knowledgeable about the different receiving inspection, corrective actions in case of a deviation, and the non-conformance procedure. The receiving personnel should be conversant with documentation or record forms used in the receiving process. 

 

Documents used

Receiving Monitoring Form

Goods Received Note

Certificate of Conformity/ Certificate of Analysis

Non-conforming form/record

Note: The receiving stage can be a Critical Control Point or a Critical Point depends on the individual company's Risk Assessment.

Check Appendix 1 and Appendix 2 for samples of Receiving Monitoring Form and Goods Received Note, respectively.

 

 

Appendix 1






Appendix 2

















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