Your How to Guide for Monitoring Critical Control Points

Why is Monitoring Important

Establish a monitoring system for each CCP is step 9/principle 4 in implementing and maintaining an effective HACCP system¹.Scheduled monitoring for each CCP checks a control measure for a critical process step is operating as expected within a defined critical limit. Codex describes the term monitor as an ‘act of conducting a planned sequence of observations or measurements of control parameters to assess whether a control measure is under control’¹.

Monitoring can significantly reduce the risk of unsafe food and drink reaching the consumer by triggering corrective actions to regain control over the process and dealing with any affected produce. Checking a target (operational) level also creates an opportunity to act before a deviation occurs at a critical limit, which can reduce unnecessary waste. Accurate and complete monitoring records demonstrate legal compliance and support validation/verification activities.

Planned Observations and Measurements

Monitoring procedures must provide rapid (real-time), accurate and repeatable results that relate back to critical limits and operational (target) levels². There are two ways to monitor a critical control point: measurement and observation. Measurements usually include temperature, time, pH, A_w, etc. Whereas observations may focus on colour change in food, visually checking operation of a metal detector or inspecting the integrity of a sieve.

Methods of Monitoring

Monitoring procedures are dependent on three factors: selected critical limits, capability of the chosen method or device to detect a deviation and process throughput. Observations and measurements can be performed on-line or off-line. Online systems may take measurements continuously or at defined intervals during the process². Continuous monitoring systems may also require additional manual checks to verify accuracy. Off-line systems take samples for rapid testing elsewhere, using instruments such as calibrated pH or A_w meters². Equipment used for monitoring must be maintained and undergo calibration at predetermined intervals to provide reliable results².

Monitoring Frequency

Monitoring of a CCP can be continuous or non-continuous².Constant monitoring is preferable but may not be possible². Non-continuous monitoring can be time based (e.g. hourly) or production based (e.g. each batch). The frequency of checks must allow process adjustments to prevent a critical limit deviation and/or permit enough time to regain control over the process and deal with any affected product following a breach².Determination of monitoring intervals is based on the following factors:

sound historical knowledge of the product and process²
level of tolerance between operating limit and critical limit²
amount of product at risk if a deviation occurs²
variations in process and product^2,3
automated or manual processes³
product uniformity³

batch size and number of batches produced daily³

history of previous checks^2,3.

The frequency of monitoring following an immediate corrective action may also need to be increased until the root cause of the problem is resolved².

Monitoring Personnel

CCP monitoring is often associated with competent production operatives because they are familiar with the process and nearby to conduct measurements and/or observations³. Production supervisors or managers and quality assurance personnel will usually oversee and verify the monitoring activity³. Designated CCP monitors must be trained in how to conduct the monitoring activity and know what to do if a deviation should occur. They should also be able to explain reasons for why monitoring is important. Training sessions and competency assessments must be recorded to show these activities were undertaken.

Monitoring Documentation and Records

Documentation, record-keeping and trend analysis are integral elements of an effective monitoring system². All documents associated with monitoring CCPs must be approved before implementation².Monitoring records and documentation are accessible for review by auditors and regulatory authorities².

Instructions for monitoring critical limits at CCPs should be communicated in a manner that is easily understood by those responsible for the activity. A documented monitoring system should include the following information:

specify what control parameter(s) will be monitored
state the frequency of measurements and/or observations
specify who is responsible for performing and overseeing the monitoring activity
define or refer to a procedure in how to conduct the monitoring activity, including details of equipment to be used²
detail where the results of monitoring are recorded with specific reference to documents and/or online systems²
list any supporting, procedures, work instructions and specifications².

Accurate monitoring records are important because they show the process was under control or appropriate corrective action was taken. A record must state the date, time and result of the monitoring activity. All monitoring records must be signed by the person conducting the monitoring activity and countersigned by the person responsible for checking records, such as a supervisor or manager. Any amendments to records must be justified, authorised, strikethrough with a single line and initialled by the person who made the correction.

Would You Like to Know More?

We cover the monitoring and other Codex steps/principles on all our accredited Level 3 HACCP for Food Manufacturing and Level 4 HACCP Management courses. Learn how to develop, implement and maintain an effective food safety and quality management systems with a MSc qualified subject matter expert.