HACCP plan for a small hazelnut processor: template with CCP records¶
Content generated by artificial intelligence — verify before application
This article was automatically compiled from a collection of hazelnut literature using artificial intelligence and may contain errors or outdated data. It serves as a starting point for further research, not as professional advice. Dosages, treatments, and timelines are informative and depend on the cultivar, location, and applicable regulations — always verify with an advisory service and official sources before implementation.
When an agricultural holding transitions from selling raw hazelnuts to processing — drying, shelling, sorting, roasting, grinding into flour or paste, packaging — it moves from primary production to food business operations. Consequently, it becomes subject to the obligation to establish, implement, and maintain a permanent procedure based on HACCP principles (Hazard Analysis and Critical Control Points). This article offers a practical, fillable HACCP plan template for a small hazelnut processor: product description, flow diagram, hazard analysis, critical control points (CCP) table, and ready-to-use record forms — monitoring logs, corrective action records, and verification records. Numerical critical limits are intentionally not invented: at every point where a number needs to be entered, a field is provided with instructions to determine the value (validate) for your own facility and equipment, because critical limits must be scientifically grounded, not copied from someone else's plan.
Why HACCP and who is it mandatory for¶
According to EU Regulation (EC) No 852/2004 on the hygiene of food, all food business operators — with the exception of primary production — must "establish, implement and maintain a permanent procedure or procedures based on the HACCP principles." Harvesting hazelnuts in your own orchard falls under primary production; as soon as you begin drying, shelling, roasting, grinding, or packaging for market placement, you become a processor, and the HACCP obligation applies to you in full scope.
In Croatia, a food business operator must register and be entered into a registry managed by the State Inspectorate (sanitary inspection) since 2021, following the entry into force of the Law on Official Controls. The establishment and implementation of procedures based on HACCP principles is prescribed by national food hygiene regulations. For specific requirements, a list of attachments, and the registration procedure, check directly with the State Inspectorate and the Ministry of Health — administrative details and forms change.
The benefit of HACCP is not merely formal-legal. Literature from the hazelnut sector highlights the advantages of introducing prerequisite programs and HACCP systems: a more effective quality assurance system for processes and finished products, compliance with legal regulations, reduction of potential risks, prevention of foodborne illnesses, reduction of costs due to product withdrawal/recalls, protection of the business's reputation, and increased consumer trust and sales.
The Seven HACCP Principles¶
HACCP is based on seven principles, which are applied after five preparatory steps (establishing the HACCP team, product description, identification of intended use and target consumer group, flow diagram creation, verification of the flow diagram on-site):
| No. | Principle | What it covers |
|---|---|---|
| 1 | Conduct hazard analysis | Identify biological, chemical, and physical hazards at each step |
| 2 | Determine critical control points (CCP) | Steps where hazards can be eliminated or reduced to an acceptable level |
| 3 | Establish critical limits | Measurable values (time, temperature, moisture, flow rate) or equipment condition |
| 4 | Establish a monitoring system for CCPs | Who, what, how, and how often measurements are taken |
| 5 | Establish corrective actions | What to do when monitoring indicates a deviation from the critical limit |
| 6 | Establish verification procedures | Confirmation that the system is working effectively |
| 7 | Establish documentation and record-keeping | Records that demonstrate the application of principles 1–6 |
Principle 3 requires special attention. Critical limits are minimum or maximum values that must be achieved to prevent, control, or eliminate a hazard — e.g., time, temperature, flow speed, moisture. A limit can also be a parameter like "metal detector switched on and functioning" or "screen present and undamaged," not necessarily a number. Crucially: the effectiveness of each CCP control must be determined and scientifically validated — a validation study determines appropriate critical limits that achieve the desired hazard reduction. Therefore, this template does not impose numbers but leaves fields for your own validation.
Prerequisite Programs (PRP) — the foundation upon which HACCP stands¶
The HACCP system functions successfully only with the application of prerequisite programs (PRP). They cover "lower-level risk" hazards and constitute basic hygiene conditions; without them, the HACCP plan hangs in mid-air. Prerequisite programs include:
- Good Hygiene Practice (GHP) — worker behavior rules, wearing protective equipment and special clothing, hair protection, prohibition of cosmetics, hand washing and disinfection procedures.
- Good Manufacturing Practice (GMP) — minimum requirements for process control and sanitation: suitable equipment and materials, location and design of premises, pest control.
- Standard Operating Procedures (SOP) — define who, why, exactly what, and how to do it; they also determine the frequency of tasks, acceptable limit values, and follow-up actions if results are unsatisfactory.
- Standard Sanitary Operating Procedures (SSOP) — pre-operational sanitation (cleanliness of equipment, utensils, and surfaces before production) and operational sanitation (cleanliness during production, worker hygiene, handling of raw materials, semi-finished products, and finished products).
For cleaning, a practical rule from the literature applies: the necessary elements — time, temperature, mechanical force, and chemical concentration — cannot be reliably applied if the equipment and facility design do not allow access. In hazelnut processing, moisture control is particularly important: low-moisture products (kernels, flour, paste) require a dry working environment to prevent contamination by environmental pathogens such as Salmonella.
PRP Control List (fillable)¶
| PRP Area | Is there a written procedure? (Yes/No) | Responsible Person | Frequency of Check | Where Recorded |
|---|---|---|---|---|
| Personnel hygiene and training | ||||
| Cleaning and disinfection (SSOP) | ||||
| Pest control | ||||
| Equipment maintenance and calibration | ||||
| Water (if used) and waste | ||||
| Raw material receipt and storage | ||||
| Allergen control and segregation | ||||
| Traceability and product withdrawal |
Step 1: Product Description (fillable form)¶
The product description is a preparatory step before hazard analysis. Fill it out for each product or group of similar products.
| Item | Entry |
|---|---|
| Product name | e.g., roasted hazelnut kernels / hazelnut flour / hazelnut paste |
| Composition / ingredients | |
| Key characteristics (aw, moisture, pH if applicable) | validate / measure |
| Treatment that destroys/reduces hazards | e.g., roasting (thermal treatment) |
| Packaging (type, material) | |
| Shelf life and storage conditions | determine based on testing |
| Labeling (incl. allergens — hazelnut is a tree nut allergen) | |
| Distribution method | |
| Intended use and target consumer group | e.g., general population; specify if for sensitive groups |
Step 2: Flow Diagram (process steps)¶
The flow diagram must be verified on-site ("walk-through") because the actual process often differs from what is on paper. A typical sequence for a small hazelnut processor:
1. Raw material receipt (hazelnuts in shell / kernels) → receiving control
2. Drying (reducing kernel moisture to a safe level)
3. Storage (dry, cool, protected from pests)
4. Shelling / shell cleaning
5. Sorting / grading (removal of moldy, damaged, foreign bodies)
6. Roasting (thermal treatment) — if applicable
7. Cooling
8. Grinding / making paste / flour — if applicable
9. Metal detection / sieving
10. Packaging and labeling
11. Finished product storage and dispatch
Not every facility will have all steps. Turkish and EU literature on hazelnuts shares a common message: HACCP for hazelnuts is built throughout the chain from harvest and post-harvest processes to processing, and the greatest risks are associated with microbiological contamination, mold development, mycotoxin formation (aflatoxin), and fat oxidation.
Step 3: Hazard Analysis (fillable table)¶
For each process step, assess biological (B), chemical (C), and physical (P) hazards. Biological hazards pose the greatest immediate threat to the consumer; for hazelnuts, molds and aflatoxin (chemical-biological hazard) and fat oxidation (qualitative-chemical) are paramount.
| Step | Potential Hazard (B/C/P) | Cause | Significant? (Yes/No) | Control Measure | Is it a CCP? |
|---|---|---|---|---|---|
| Raw material receipt | C: aflatoxin; B: molds | Moisture/moldy raw material | Supplier specification, visual inspection, sampling | ||
| Drying | B: mold growth; C: mycotoxin | Excessive kernel moisture | Drying to target moisture; time/temperature control | candidate for CCP | |
| Storage | B: molds; P: pests | Moisture, temperature, rodents/insects | Climate control, PRP pest control | ||
| Sorting/grading | C: aflatoxin; P: foreign bodies | Missed moldy/damaged nuts | Manual/optical sorting, training | candidate for CCP | |
| Roasting | B: vegetative pathogens | Insufficient thermal treatment | Roasting time/temperature | candidate for CCP | |
| Metal detection / sieving | P: metal, fragments | Equipment wear | Metal detector / sieve | candidate for CCP | |
| Packaging/labeling | C: incorrect allergen declaration | Wrong label | Label check, allergen control |
Note: which steps will actually be CCPs depends on your process and the result of the decision tree. A step is a CCP if it is the place where the hazard can be eliminated or reduced to an acceptable level, and no one else can remove it later. If roasting is not performed, drying and sorting (aflatoxin control) usually carry the greatest weight.
Step 4: CCP Table (Core Plan Template)¶
This is the core of the HACCP plan. Numerical limits are intentionally left blank — determine them through validation for your specific equipment, batch, and cultivar, and support them with documentation (validation study, scientific paper, guideline, or equipment supplier data).
| CCP | Hazard | Critical Limit | Monitoring: What | Monitoring: How | Frequency | Who | Corrective Action | Verification | Record |
|---|---|---|---|---|---|---|---|---|---|
| CCP-1 Drying | Mold/aflatoxin | Kernel moisture ≤ ___ % (validate) | Kernel moisture | Moisture meter / laboratory | ___ (per batch?) | ___ | Re-dry/extend drying; segregate batch | Weekly moisture meter calibration check; record review | Drying log |
| CCP-2 Sorting | Aflatoxin/foreign material | Visual criteria: no moldy/damaged nuts; no foreign material | Defect rate | Visual/optical sorting, control sample | ___ | ___ | Re-sort; reject batch; sample for aflatoxin | Periodic sample analysis; staff supervision | Sorting log |
| CCP-3 Roasting | Pathogens | T ≥ ___ °C for ___ min (validate) | Temperature and time | Thermometer/oven recorder | per batch | ___ | Re-roast/extend roasting time; segregate batch | Thermometer calibration; record review | Roasting log |
| CCP-4 Metal Detection | Metal foreign material | Detector "on and operational"; test sample Fe/non-Fe ___ mm | Detector operation | Test pieces (Fe, non-Fe, stainless steel) | start/end of shift + ___ | ___ | Stop line; segregate product since last good test; inspect | Verification of test pieces; service | Metal detection log |
A critical limit can also be non-numerical ("detector on and operational," "sieve present and undamaged") — this is legitimate and recommended where a measurable parameter is an equipment condition.
Step 5: Monitoring Log Form (Fillable)¶
Monitoring is best conducted through physical and chemical testing as well as visual observations. The monitoring log is a daily/batch record filled out by the operator. Template (one row per measurement):
| Date | Batch/Lot | CCP | Measured Value | Critical Limit (from plan) | In Limit? (Yes/No) | If No → Corr. Action Record No. | Operator Signature | Time |
|---|---|---|---|---|---|---|---|---|
Guidelines for filling out: - Record the actual measured value, not just "OK". A number (e.g., moisture, °C) has evidentiary value; "OK" does not. - Monitoring can be continuous or periodic (e.g., per batch, every hour) — align this with what is stated in the plan. - For every "No," enter the number of the associated corrective action record for traceability.
Step 6: Corrective Action Record Form (Fillable)¶
Principle 5 requires pre-defined corrective actions to be taken when monitoring indicates a deviation from the critical limit and the CCP is not under control. Each deviation receives its own record:
| Field | Entry |
|---|---|
| Record No. | |
| Date and time of deviation | |
| CCP and batch/lot | |
| Description of deviation (measured value vs. limit) | |
| Cause (if known) | |
| Action on product (hold / rework / segregate / discard) | |
| Action on process (repair, re-calibration…) | |
| Disposition of affected product since last correct measurement | |
| Who performed the action | |
| Signature and date | |
| Verified by (responsible person) |
Best practice: pre-define what happens to product produced since the last correct measurement until the deviation is detected — this product is suspect and must be segregated or further checked.
Step 7: Verification and Record-Keeping Form¶
Verification (Principle 6) confirms that the plan works as intended and is conducted independently of monitoring — it includes additional testing where appropriate, record reviews, instrument calibration, and periodic review (validation) of critical limits. For a small processor, a simple verification plan is sufficient:
| Verification Activity | Frequency | Who | Acceptance Criteria | Record |
|---|---|---|---|---|
| Review of monitoring logs and corrective action records | ___ (e.g., weekly) | ___ | All completed and signed | |
| Calibration of thermometers/moisture meters | ___ | ___ | Within permissible deviation | |
| Laboratory analysis (e.g., aflatoxin, moisture) | ___ | external lab | Within legal limits | |
| Re-validation of critical limits | upon change of product/process/equipment | HACCP team | Limit remains effective | |
| Internal HACCP/PRP audit | ___ (e.g., annually) | ___ | No major non-conformities |
All HACCP procedures (hazard analysis, determination of CCPs, critical limits, review) must be signed by the HACCP team leader and the responsible person at the facility, and the procedures described in the documentation must match what is actually done in production.
Traceability — Linking to HACCP¶
HACCP only makes sense if you can track the product forward and backward through the chain. A traceability system enables the identification of one or more batches (lots) on the market and the effective withdrawal of non-compliant goods. The Croatian "Proven Quality" scheme specifies which data the producer must maintain:
- Production process traceability: producer, address, plot name/ID, land parcel identification, production field identification number, cultivar, harvest date, pass (first/second), orchard age.
- Finished product traceability: type, cultivar, quantity, delivery date, and storage location.
Practically: for hazelnuts, implement a clear batch (lot) code that traces back to the production date, raw material, and process parameters. This way, in case of a problem, you withdraw only the affected lots, not the entire production run.
Common Mistakes by Small Processors¶
- Copying others' numbers. Critical limits (moisture, temperature, roasting time) must be validated for your own equipment and product. Another company's "≤ X %" value is not proof — it may be incorrect for your dryer or oven.
- HACCP without PRPs. The plan cannot function if hygiene, cleaning, pest control, and maintenance are not established and recorded.
- "OK" instead of measured value. A record without a number loses evidentiary value before inspectors and in the event of a recall.
- Too many CCPs. If you declare everything a CCP, you control nothing. A CCP is only a step where a hazard is actually eliminated or reduced to an acceptable level, and cannot be removed later.
- Plan that does not match reality. The flow diagram and procedures must be verified on-site and updated with every change in product, process, or equipment.
- Ignoring allergens. Hazelnuts are an allergen from the tree nut group; labeling and separation from other lines must be controlled.
- Inconsistent record-keeping. Without proper paper or digital records, you lose key product information and expose yourself to penalties in case of deviations.
How to Start Your HACCP Plan — Summary Sequence¶
- Assemble the HACCP team (can be a single person in a micro-facility, with external expert support).
- Establish and document prerequisite programs (DHP, DPP, SOP, SSOP).
- Complete the product description and draw the flow diagram; verify it on-site.
- Conduct the hazard analysis and determine CCPs.
- For each CCP, validate the critical limit and support it with documentation.
- Implement forms: monitoring log, corrective action record, verification plan.
- Train staff and begin recording from the first day of production.
- Verify and update the plan with every change and periodically (e.g., annually).
Note on numbers: all ranges and criteria mentioned in this article are informative and depend on cultivar, equipment, location, and applicable regulations. Determine specific critical limits through validation, and check legal limits (e.g., for aflatoxin), registration forms, and procedures at official sources (State Inspectorate, Ministry of Health / HAH, Narodne Novine) and with advisory services.
Sources¶
This article is an AI summary generated from an internal collection of hazelnut literature (RAG corpus) supplemented by public sources. Numerical values are not fabricated; where a source does not provide a number, a field for own validation is provided. Main sources used:
- Industry Handbook for Safe Processing of Nuts (GMA Nut Safety Task Force, 2016) — seven HACCP principles, critical limits, validation, corrective actions, and verification (RAG corpus).
- Cascading Use of Hazelnut and Aronia By-products / related Croatian source (2025) — HACCP principles, prerequisite programs (DHP, DPP, SOP, SSOP), benefits of implementation (RAG corpus).
- Sustainable Farming Standards — SFS Brochure (2021) — overview of the seven HACCP principles (RAG corpus).
- Fındık Hasat Teknolojisi / Ordu İlindeki Fındık İşleme Tesisleri (2007–2017) — HACCP application in the hazelnut chain, hazard and CCP definitions (RAG corpus).
- OMAFRA Factsheet — Growing, Harvesting and Food Safety; Guía de buenas prácticas (avellano, Asturias, 2020) — operational controls/PRP in hazelnut processing (RAG corpus).
- FDA — Hazard Analysis and Risk-Based Preventive Controls / Draft Guidance (2016) — prerequisite programs and sanitation (RAG corpus).
- "Proven Quality" Product Specification (2021) — requirements for production process and finished product traceability (RAG corpus).
- Regulation (EC) No 852/2004 on the hygiene of foodstuffs — obligation to implement a procedure based on HACCP principles — https://eur-lex.europa.eu/eli/reg/2004/852/oj?locale=hr
- State Inspectorate of the Republic of Croatia — Recording and maintaining registers of food business operators and premises — https://dirh.gov.hr/
- Ministry of Health of the Republic of Croatia — Registration of food business operators and premises — https://zdravstvo.gov.hr/
- Croatian Food Agency (HAH) — Basic Guidelines for Hygienic Food Production — https://www.hah.hr/pdf/osnovne_upute.pdf
- FDA — HACCP Principles & Application Guidelines — https://www.fda.gov/food/hazard-analysis-critical-control-point-haccp/haccp-principles-application-guidelines
- Pennsylvania / PCCHD — Downloadable Blank HACCP Forms & Flow Chart (form templates) — https://www.pcchd.org/DocumentCenter/View/1890/HACCP-Plan-Form-Fillable-Blankpdf