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CGMPs and HACCP: The Dukes of Hazards
In recent blog posts, we've discussed CGMPs—Current Good Manufacturing Practices. These are the standards and procedures set by the FDA to ensure that food products are safe, of high quality, and fit for consumption.
This article will focus on the different types of hazards that can occur during food processing, as well as the controls that can be implemented to reduce these risks. Many CGMPs are specifically designed to manage these hazards, making them a valuable foundation for developing a HACCP plan.
So, what exactly is considered a hazard? There are three main categories: biological, physical, and chemical.
Let’s start with biological hazards. The Centers for Disease Control (CDC) classifies biohazards into four levels. Level One includes microorganisms like bacteria that can spread through contact or airborne transmission, such as E. coli. Each level becomes more dangerous, with Level Four being the most severe, including viruses like Ebola and Marburg.
Physical hazards are perhaps the most straightforward to understand. These include any foreign objects that could cause illness or injury when consumed. Things like bone fragments, needles, wood splinters, packaging pieces, insects, or dirt are all examples. Contamination can come from raw materials, improper production practices, or poorly maintained facilities. Think back to Upton Sinclair's *The Jungle*, which exposed the unsanitary conditions in the meatpacking industry. While modern food safety regulations have improved things significantly, even small changes in processes can introduce new physical risks.
Chemical hazards are also a major concern. Some are unavoidable, such as pesticides, herbicides, antibiotics, and additives used in food processing. Improper storage or use of cleaning agents can also lead to contamination. Allergens fall under this category too. The FDA has identified eight major food allergens: milk, eggs, fish, shellfish, tree nuts, peanuts, wheat, and soy. To protect consumers, the FDA sets strict limits on these substances in food products.
How do food processors control these hazards? A solid first step is to create a written food safety plan based on FDA CGMPs. These guidelines help identify and manage potential risks. For an extra layer of protection, many companies implement a HACCP plan. The first step in HACCP is conducting a hazard analysis. Following HACCP principles provides a structured approach to food safety, helping identify critical control points and establish monitoring, corrective actions, and verification procedures.
CGMPs can be used alone or in combination with HACCP to maintain food safety. After all, we're only human—and that means mistakes can happen. That’s why having proper controls is essential to minimize risks. Over the years, we’ve worked with many food producers, and we know that food safety is taken very seriously. At a minimum, every food company should have someone on staff who understands how to identify and manage hazards.
We’d love to hear from you—how does your company handle food hazards? What strategies have worked well, and what hasn’t? Share your experiences with us. And if you want to dive deeper into the topic, check out our white paper *Understanding GMPs*.