An Introduction to HACCP Process Flow Diagrams

BRC Global Standards. Trust in Quality

HACCP Process Flow Diagrams

HACCP Process Flow Diagrams

A key step in the HACCP process, and one that many sites find challenging, is the design of an accurate process flow diagram.

The process flow diagram (simply referred to as ‘the diagram’ in this short guide) is a key document that your site’s food safety hazard
study will be based on. So it’s important that careful consideration and an understanding of the site’s processes are known to ensure
completeness and accuracy.

1.0 Requirements of the BRC Global Standard for Food Safety

There are two requirements in the BRC Global Standard for Food Safety relating to HACCP process flow diagrams:

Clause 2.5.1 states:

A flow diagram shall be prepared to cover each product, product category or process. This shall set out all aspects of the food process
operation within the HACCP scope, from raw material receipt through processing, storage and distribution. As a guide, this should
include the following, although this is not an exhaustive list:

• Plan of premises and equipment layout

• Raw materials including introduction of utilities and other contact materials e.g. water, packaging

• Sequence and interaction of all process steps

• Outsourced processes and subcontracted work

• Process parameters

• Potential for process delay

• Rework and recycling

• Low/high care/high risk area segregation

• Finished products, intermediate/semi-processed products, by-products and waste.

Clause 2.6.1 states:

The HACCP food safety team shall verify the accuracy of the flow diagrams by onsite audit and challenge at least annually. Daily and
seasonal variations shall be considered and evaluated. Records of verification of flow diagrams shall be maintained.

2.0 Food safety hazard analysis

Effective hazard analysis requires considerable knowledge of the product(s) and process(es) in operation on the site. Therefore the HACCP
system incorporates a number of steps to gather this information including:

• Description of the product

• Identification of the intended use

• Construction and verification of a process flow diagram

The aim is to use the information gathered to ensure every aspect is considered during the food safety hazard analysis.

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 Raw Ingredients
Raw Ingredients
10. Tumbling 11. Waste (Brine)
HACCP Process Flow Diagrams
Deep Fat Frying
(See HACCP Study A1)
Deep Fat Frying
(See HACCP Study A1) LOW RISK
12. Cooking
3.0 What does a good process flow diagram look like? (≥Xoc for Y minutes) HIGH RISK
Steamed Ingredients
All Process Stages Final Products
(See
There’s no set pattern or HACCP
format for Study B1) However, it’s important to show all the steps in the process, from raw materials right
the diagram.
Steamed Ingredients
All Process Stages Final Products
(See HACCP Study B1)
through to final products. 13. Cooling Blast Chill
(<Xoc within Y hours)
The most common format is a linear diagram:

14. Chilled Storage (X-Yoc)

Raw Materials (if required due to delay
in cutting)
Raw Materials

17. Plastic Trays, Film

All Process Stages 15. Cutting 16. Waste
Lids & Labels
All Process Stages

18. Packaging Store 19. Disinfection

Product 20. Packing & Labelling

Product

All products must be covered in the diagram, so if your site has a wide range of similar products/processes
21. Date Coding a modular option may be
preferable. Otherwise a separate linear diagram is needed for each product i.e. 20 products would need 20 linear process flow diagrams.

The typical structure of a modular diagram is:

22. Metal Detection
Raw Materials
HIGH RISK
Raw Materials
ENCLOSED
PRODUCT AREA
23. Chilled Storage (X-Yoc)
All Process Stages All Process Stages All Process Stages
All Process Stages All Process Stages All Process Stages

24. Chilled Dispatch (X-Yoc)

Product A Product B Product C
Product A Product B Product C

An alternative modular diagram may look like this:

Raw Ingredients

Deep Fat Frying

(See HACCP Study A1)

Steamed Ingredients
All Process Stages Final Products
(See HACCP Study B1)

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HACCP Process Flow Diagrams

If you use a modular or generic diagram, take care to ensure all steps and all products are included in the diagram. If your site produces
multiple products that are considerably different or require different processes, you’ll need to have several separate diagrams.

In addition to the process steps, the diagram also needs to contain:

• All raw materials used in the production of the product(s) including the introduction of utilities and other contact materials e.g. water or
packaging

• Details of any outsourced or subcontracted process i.e. any activity that is part of the production process but that doesn’t occur onsite

• The process parameters e.g. time or temperature

• Rework or recycling

• Low risk, high care and high risk segregation

• Routes taken by waste products

• All finished products, intermediates, semi-processed products or by-products.

Two examples of completed process flow diagrams are shown in appendix 1.

4.0 Verification of the process flow diagram

An important step in the development and maintenance of the diagram is verification (requirement 2.6.1 of the BRC Standard). This
requires effective confirmation that the diagram is an accurate representation of the actual activity within the production facilities.

The best verification technique is for part or all of the HACCP team to complete a physical walk-through of the process. In other words, the
diagram is taken into the production areas and compared to the actual activity taking place. During the course of the BRC audit, the auditor
will also assess the accuracy of the diagram, probably using this same technique.

The diagram in appendix 1.1 shows the process for the manufacture of a walnut biscuit, which on initial inspection looks accurate. However,
the site is expected to examine each step to confirm this accuracy. In this example it would be particularly advisable to check whether:

• All of the times and temperatures are correct

• There are really only five ingredients (all raw materials must be listed)

• The flour and sugar are sieved through the same size sieve

It’s recommended that any new or amended processes or products are verified as soon as production commences and all diagrams must
be verified at least annually.

5.0 The importance of keeping good records

Your site should maintain full records of the diagrams and all verification activity. For example, a verification record could include a fully
annotated diagram showing:

• The date and time of the verification

• Product(s) being manufactured at the time the activity was observed

• Any amendments or alterations that were noted

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 HACCP Process Flow Diagrams

Alternatively, a separate report could be produced in the format of an internal audit.

The records should also be signed to confirm who completed the verification.

Quick Tips

• Ensure all relevant information is incorporated in the diagram

• Ensure all ingredients are incorporated including water, additives and packaging

• Consider all shifts including night or weekend production

• Consider seasonal or occasional production activities

These short guides are designed for companies involved in the enrolment program and aim to help you interpret the Standard, and design
robust systems and procedures that meet the requirements. Examples are given to explain the types of documents and procedures and
the level of detail typically required. However, you’ll need to consider the context relevant to your business. The implementation of the
Standard, and whether a resulting system is considered to be conforming or non-conforming by an auditor, is an objective judgement
which can only be based on the evidence collected and observations made during the audit.

Further details regarding the BRC Global Standard for Food Safety can be obtained from [email protected]

Appendix 1: Examples of completed process flow diagrams

The purpose of the appendices overleaf is to provide clarity on the format and the information to include in process flow diagrams. They
are not intended to provide numerical data that is normal or safe for any specific product. Therefore ‘X’ and ‘Y’ have been used instead of
numerical values to avoid any misunderstanding or confusion. Your own site’s flow diagrams are, of course, expected to contain the full
numerical information relevant to the product(s).

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HACCP Process Flow Diagrams

A1.1 Walnut Biscuit

1. Flour 2. Sugar 3. Walnuts 4. Butter

5. Bulk Storage (Ambient) 6. Ambient Storage 7. Chilled Storage (X-Yoc)

9. Tempering
8. Sieving (Xµm)
(Ambient ≤X hours)

10. Water 11. Weighing Up

12. Mixing

13. Forming

15. Rework

14. Cutting 16. Waste

17. Baking
(≤Xoc, Y minutes)

18. Cooling
(Ambient, X minutes)

19. Pre-Printed 20. Packaging Store 21. Packing 22. Waste

Plastic Wrap

23. Date Coding

24. Metal Detection

25. Ambient Storage

26. Dispatch

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 HACCP Process Flow Diagrams

A1.2 Cooked Cured Meat

1. Salt (NaCl) 2. Nitrite Curing Salt 3. Trimmed Pork Joints

4. Ambient Storage 5. Frozen Storage (<Xoc)

7. Curing Brine
6. Water 8. Injection 9. Thaw (Xoc for Y-Z hours)
Preparation

10. Tumbling 11. Waste (Brine)

12. Cooking LOW RISK

(≥Xoc for Y minutes) HIGH RISK

13. Cooling Blast Chill

(<Xoc within Y hours)

14. Chilled Storage (X-Yoc)

(if required due to delay
in cutting)

17. Plastic Trays, Film

15. Cutting 16. Waste
Lids & Labels

18. Packaging Store 19. Disinfection 20. Packing & Labelling

21. Date Coding

22. Metal Detection

HIGH RISK
ENCLOSED
PRODUCT AREA
23. Chilled Storage (X-Yoc)

24. Chilled Dispatch (X-Yoc)

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