| Receiving and raw-material inspection |
Contamination, damaged packaging, incorrect temperature, or undeclared allergen risk |
Temperature probes, barcode or label verification, visual inspection systems |
Product temperature, packaging integrity, lot identity, supplier documentation |
Receiving log, calibration records, lot traceability record, acceptance criteria |
Hold, reject, or investigate the lot; document the decision |
Supports hazard analysis, monitoring, record keeping, and verification |
| Thermal processing |
Survival of pathogenic microorganisms due to inadequate time or temperature |
Calibrated temperature sensors, data loggers, automated process controls |
Time, temperature, product flow, and process conditions against validated limits |
Continuous or batch records, calibration certificates, validation study, review sign-off |
Stop or isolate affected product, correct the process, and assess product disposition |
A measurable critical limit is monitored at a process step identified as a CCP |
| Metal contamination control |
Ferrous, non-ferrous, or stainless-steel fragments |
In-line metal detection system with automatic reject |
Detector challenge performance, product passage, reject operation, and alarm status |
Start-up and scheduled challenge tests, reject verification, alarm records, maintenance logs |
Quarantine products since the last satisfactory check and investigate the source |
Provides documented monitoring where the hazard analysis identifies metal as a significant hazard |
| Foreign-body inspection |
Glass, stone, bone, dense plastic, or other physical contaminants |
Food X-ray inspection system, depending on product and packaging |
Detection system sensitivity, image quality, reject function, and product coverage |
Performance-test records, reject confirmation, calibration or verification records |
Stop the line, isolate potentially affected units, identify the contamination source |
Supports monitoring and verification of a physical-hazard control measure |
| Fill-weight and portion control |
Underweight packs, incorrect formulation, or loss of process control |
Automatic checkweigher and statistical process monitoring |
Net weight, product count, reject accuracy, and trend deviations |
Weight records, verified test weights, rejection reports, and equipment checks |
Adjust the filling process and hold product produced during the deviation |
Usually supports quality or legal metrology controls; may support HACCP when linked to a food-safety hazard |
| Label and allergen verification |
Incorrect label, missing allergen declaration, or wrong product-pack combination |
Vision inspection, optical character recognition, barcode verification |
Label presence, product code, date code, allergen statement, and packaging match |
Line-clearance checklist, label verification log, changeover approval, reject records |
Stop production, segregate incorrectly labeled units, relabel or dispose according to procedure |
Supports allergen management, traceability, corrective action, and verification activities |
| Cold-chain monitoring |
Microbial growth caused by improper storage or transportation temperature |
Fixed temperature sensors, data loggers, and automated alarms |
Storage, transport, and product temperatures against established limits |
Temperature charts, alarm history, calibration records, and product-release review |
Place product on hold, evaluate time-temperature exposure, and restore compliant conditions |
Demonstrates monitoring of a control measure when temperature is determined to be critical |
| Final release and traceability |
Release of product with unresolved deviations or incomplete traceability |
Integrated production records, lot coding, database review, and release checklist |
Completed CCP records, corrective actions, verification results, and lot status |
Batch record, deviation report, traceability test, authorization record |
Block release, conduct documented review, and initiate withdrawal or recall procedures when necessary |
Supports record keeping, verification, validation, and the ability to respond to nonconforming product |