If you work in the food industry you have surely heard of Hazard Analysis and Critical Control Points. Did you know that Mapex’s MES solution is a tool that helps you guarantee the effectiveness of your HACCP plan?
What is HACCP?
Hazard Analysis and Critical Control Points (HACCP) is a preventive system that guarantees food safety by identifying and controlling possible hazards at all stages of the food production chain.
This approach, developed in the 1960s by NASA in collaboration with the United States Army Laboratories and the Pillsbury company, focuses on the prevention of biological, chemical and physical hazards.
HACCP importance in the food industry
The implementation of HACCP is crucial in the food sector for several reasons.
Pollution prevention: HACCP makes it possible to identify and control critical points where contamination can occur, significantly reducing the risk of foodborne illness outbreaks.
Normative compliance: many countries and international organizations, such as the Codex Alimentarius Commission, require the implementation of HACCP to ensure compliance with food safety standards.
Consumer confidence: the adoption of HACCP improves consumer confidence by ensuring that food products are safe for consumption.
Operating efficiency: by focusing on prevention, HACCP helps companies avoid costly product recalls and protects brand reputation.
The seven principles of HACCP
HACCP is based on seven fundamental principles.
1. Hazard analysis
Identification and evaluation of hazards that may affect food safety. Hazards can be biological (bacteria, viruses, parasites), chemical (pesticide residues, toxins) or physical (glass fragments, metal).
2. Identification of Critical Control Points (CCP)
A CCP is a step in the production process where controls can be applied to prevent, eliminate or reduce to acceptable levels a significant risk identified in the hazard analysis phase.
3. Establishment of critical limits
Critical limits are criteria that must be met to ensure that a CCP is under control. These may include parameters such as temperature, time, humidity level, pH, etc.
4. Monitoring of CCPs
This stage consists of the planned observation or measurement of critical limits in CCPs to ensure that they are kept under control and there are no deviations.
5. Application of corrective actions
Corrective actions should be implemented when a CCP is not under control and critical limits have been exceeded. It is necessary to correct the problem and ensure that the affected product does not reach the consumer.
6. HACCP system verification
This Verification involves the application of additional methods, procedures and tests, in addition to monitoring, to confirm that the HACCP system is functioning correctly.
7. Documentation and registration
Creating and maintaining detailed records of all HACCP procedures, follow-ups, corrective actions and verifications to facilitate audit processes.
How does the Mapex MES solution help you comply with your HACCP plan?
The Mapex MES solution facilitates compliance with HACCP principles for companies in the food industry thanks to the following functionalities.
Monitoring of production processes in real time
The data capture automation and real-time control of production processes is crucial for compliance with the HACCP plan, as it allows immediate detection of deviations.
This approach ensures that any anomalies in critical parameters, like temperature and pH, are identified and corrected immediately, preventing possible contamination and guaranteeing food safety.
The ability to react in real time and apply corrective actions with agility significantly reduces the risk of non-compliant products reaching the consumer and increases the level of customer satisfaction and trust in the company.
Documentation digitization
The documentation digitization for HACCP compliance gives way to easy and reliable access to information.
Likewise, a MES is very useful for complete traceability management, allowing detailed monitoring from the receipt of raw materials to the dispatch of the final product.
In this sense, digitalization is also a great ally in terms of regulatory compliance by providing clear and accessible documentation, something crucial to pass audits and verifications.
Data analysis and continuous improvement
The MES system is a very powerful tool for analysis of data and continuous improvement, since it collects and centralizes information from all production processes on a single platform.
This monitoring capability allows you to identify trends, patterns and possible weak points in the quality control system. By analyzing this data, companies can implement targeted and preventative improvements, ensuring that CCPs are always kept under control.
In addition, the MES facilitates the constant verification and validation of processes, providing detailed reports that help evaluate the overall effectiveness of the HACCP system. This not only ensures regulatory compliance and improves food safety, but also optimizes operational efficiency and reduces costs associated with product failures and recalls.
Integration with other systems
A MES solution like Mapex integrates with other systems such as ERP or CMMS. This two-way communication between tools allows a holistic and coordinated vision of all processes.
For example, when connecting the MES with the CMMS, maintenance programs can be established for critical equipment to ensure its reliability and effectiveness in risk control.
Additionally, integrating the MES with other systems improves traceability and regulatory compliance by providing a centralized platform for CCP documentation and monitoring.
Food safety is a global priority, and HACCP is a proven and effective approach to ensuring it. As we have seen, the integration of an MES in the implementation of HACCP not only facilitates compliance with its principles, but also improves the operational efficiency, competitiveness and profitability of the business.
For more information about the functionalities of our MES platform for quality control and food safety, do not hesitate to contact us through this form.