Last Updated on December 2, 2025 by Melissa Lazaro

Why Hazard Analysis Matters in HACCP

When I sit down with food manufacturers starting HACCP for the first time, the same concern always comes up: “Where do we begin?”

Hazard analysis is where everything starts. If you get this step right, the rest of your HACCP plan becomes much easier. If you skip steps or rush through it, you’ll feel the consequences later during audits, recalls, or non-conformities.

In this guide, you’ll learn how to identify food-safety hazards, determine which ones are significant, and decide how to control them. I’ll walk you through practical examples, explain what most businesses overlook, and give you a process you can use immediately—whether you’re building a new HACCP plan or updating an existing one.

By the end, you’ll know how to confidently perform a hazard analysis that aligns with Codex HACCP, FSSC 22000, ISO 22000, BRCGS, or any GFSI-recognized scheme.

Understanding Hazard Types in HACCP — Biological, Chemical & Physical Hazards

Before diving into forms and matrices, it helps to understand what you’re actually looking for.

A hazard is anything that can cause harm to the consumer. In HACCP, we typically group hazards into three types:

• Biological — pathogens like Salmonella, Listeria, E. coli, mold, parasites.
• Chemical — allergens, pesticides, cleaning chemical residues, migration from packaging.
• Physical — metal fragments, bone chips, glass shards, wood splinters.

One of the easiest ways to start identifying hazards is by looking at your product, raw materials, and process steps. For instance:

• Raw chicken naturally carries biological risks.
• Cream fillings may introduce allergen risks.
• Glass packaging increases physical risks.

Pro Tip: Review recalls in your sector. Industry patterns usually repeat.

Common Mistake: Some teams list every possible hazard without deciding which ones are realistic. The goal isn’t to create a dictionary—it’s to identify what’s credible in your process.

Mapping the Process Flow — Identifying Where Hazards May Occur

Once you understand hazard types, the next step is mapping where hazards can occur.

Start with a process flow diagram covering everything from receiving raw materials to shipping the finished product. Then verify it onsite—don’t rely solely on a diagram someone made years ago.

A typical sequence looks like:

1. Receiving materials
2. Storage
3. Processing or cooking
4. Cooling
5. Packaging
6. Distribution

During a recent project with a bakery, the team initially missed a hazard because they never walked through the cooling area. The cooling rack was near an open door, so pests and airborne contamination were real risks—but the diagram didn’t show that.

Pro Tip: Highlight any steps that involve people, equipment changes, waste, movement between areas, or environmental exposure.

Common Mistake: Teams often treat the process flow as “done” once drawn. In reality, it should evolve as your facility changes.

Evaluating Severity and Likelihood — Using a Hazard Risk Assessment Matrix

Once hazards are identified, the next question is: How risky are they?

This is where a hazard evaluation matrix becomes useful. Most systems use a simple scoring method:

• Severity: How serious would the outcome be if the hazard reached the customer?
• Likelihood: How probable is it that the hazard will occur without control measures?

You might use ratings such as Low–Medium–High or a 1-5 scale.

For example:

Hazard	Severity	Likelihood	Risk Level
Metal in product	High	Low (with metal detector)	Medium
Undeclared allergen	High	Medium	High
Pathogens in raw vegetables	Medium	High	High

Common Mistake: Letting personal assumptions shape scoring. Always rely on data—complaints, testing history, scientific evidence—not opinions.

Determining Significant Hazards — What Needs Control and Why

Not all hazards require a CCP or major control. Some are covered by good prerequisite programs like cleaning, pest control, or supplier management.

A hazard becomes significant when:

• It’s reasonably likely to occur
• AND it could cause serious harm

For example:

• A peanut contaminating a chocolate bar is significant.
• A tiny paper fiber from packaging? Usually not—but document the reasoning.

Pro Tip: Write justification statements clearly. Auditors appreciate logic more than perfect formatting.

Selecting Control Measures — Preventive Strategies That Work

Once significant hazards are identified, the next step is choosing how to control them.

Examples include:

• Thermal processing to destroy pathogens
• Allergen separation and validated cleaning
• Supplier approval programs
• Metal detection or x-ray systems
• Environmental monitoring

One manufacturer I worked with invested in a metal detector but never validated it. The machine was running—but it wasn’t actually detecting the smallest risk-relevant sizes. That oversight could’ve led to a major recall.

Common Mistake: Implementing controls without confirming the team can monitor, verify, and maintain them consistently.

Controls aren’t just equipment or paperwork—they’re routines you can rely on.

FAQs — Hazard Analysis Explained Simply

How detailed should the hazard analysis be?
Detailed enough that anyone reading it can understand how you arrived at your decisions. Clear logic is more important than long text.

Does hazard analysis need scientific references?
Yes. Regulatory agencies and certification bodies expect decisions to be supported by valid data—FDA, EFSA, scientific literature, or supplier specifications.

How often should hazard analysis be updated?
Update it whenever there’s a change in product, process, equipment, ingredients, suppliers, regulation, or after an incident or recall.

Conclusion — Your Next Step Toward a Strong HACCP Plan

A well-built hazard analysis lays the foundation for CCP identification, monitoring, verification, validation, and ultimately certification. When this step is done carefully, everything downstream becomes smoother—not just for compliance, but for real-world food safety.

If you need help building your hazard matrix or reviewing your existing HACCP plan, now’s the time to take the next step. Whether it’s templates, coaching, or a full review, getting expert eyes early can save you time, stress, and costly mistakes later.