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Module 7 · Creating the HACCP System0% complete · 8 slides left
HACCP Level 3
HACCP Level 3
Module 7
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Introduction
Introduction

With the team in place, the products described and the prerequisites working, the HACCP system is built around a flow diagram of the process.

This module covers steps 4 and 5: constructing the flow diagram, and confirming on site that it is accurate. The confirmed diagram is the map that the whole hazard analysis will follow.

Step 4: The Flow Diagram
Step 4: The Flow Diagram

A flow diagram is a simple step-by-step picture of everything that happens to the food, from receiving raw materials to the final product reaching the customer.

  • It should show every step in the correct order, with nothing left out.
  • It should include inputs, such as ingredients, packaging and water.
  • It should show where food is held, reworked, returned or wasted.
  • It should be clear and simple enough for anyone to follow.
Example: A Cook-Chill Process
Example: A Cook-Chill Process

A typical flow diagram for a cook-chill dish might include these steps:

  • Purchase, and receipt of deliveries.
  • Chilled, frozen and dry storage.
  • Preparation.
  • Cooking.
  • Cooling.
  • Chilled storage.
  • Reheating.
  • Hot holding and service.

Each of these steps will be examined for hazards in the next module.

Linear and Modular Plans
Linear and Modular Plans

A simple business with only a few products can use a linear plan, with one flow diagram for each product.

A kitchen may produce hundreds of dishes. It uses a modular, or generic, plan instead, grouping dishes by the way they are made, for example:

  • Foods that are not cooked, such as salads and sandwiches.
  • Foods that are cooked and served hot straight away.
  • Foods that are cooked, cooled, and served cold or reheated later.

Each group follows the same flow, with the same hazards and controls. This is how simplified catering systems work.

Step 5: Confirm the Flow Diagram On Site
Step 5: Confirm the Flow Diagram On Site

A flow diagram drawn in an office often misses what really happens. The HACCP team must walk the process, during normal working, and check every step against the diagram.

  • Watch each stage on different shifts, and when it is busy.
  • Talk to the staff who actually do the work.
  • Look for steps that were missed, such as defrosting, rework or temporary storage.
  • Correct the diagram, and record that it has been confirmed.
Preparing for Hazard Analysis
Preparing for Hazard Analysis

Once the flow diagram has been confirmed, the team prepares a hazard analysis worksheet. For each step on the diagram, it will record:

  • The potential hazards.
  • How likely and how severe each hazard is.
  • The control measures.
  • Whether the step is a critical control point.

From here, the team applies the seven principles, starting with hazard analysis.

Summary

In this module, you have learned that:

A flow diagram maps every step of the process, from receipt to the customer, and is the basis of hazard analysis.

A simple business can use a linear plan, while a kitchen with many dishes groups them in a modular plan.

The diagram must be confirmed on site, so that it matches what actually happens.

In the next module, we will begin applying the seven principles, starting with hazard analysis.

Knowledge Check
Why must the HACCP team confirm the flow diagram on site?
Select one answer, then press Check.
To make it look professional
Because the law requires colour printing
To make sure it matches what actually happens in the process
It is not necessary
Correct. Walking the process shows whether the diagram matches reality, and catches any missing steps.
Not quite. Think about what can be missed when a diagram is drawn in an office, and try again.
Next Module →Answer the question to unlock the next module.
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