How are corrective actions determined and implemented when deviations from critical limits occur?

When a deviation from a critical limit occurs at a critical control point (CCP), predetermined corrective actions must be implemented to address the deviation and prevent potentially unsafe or non-compliant product from reaching consumers. Corrective actions are determined during the development of the HACCP plan and are specific to each CCP and critical limit. The corrective action plan should outline the steps to be taken to identify the cause of the deviation, correct the process, prevent recurrence, and evaluate the affected product. First, the process should be immediately stopped to prevent further deviations. The cause of the deviation should be investigated to determine why the critical limit was exceeded. This may involve checking equipment, reviewing procedures, and interviewing personnel. The process must be corrected to bring it back into control and within the established critical limits. This may involve adjusting equipment settings, repairing malfunctioning equipment, or retraining personnel. Any product that was produced during the deviation period should be evaluated to determine if it is safe and meets all regulatory requirements. This may involve testing the product for pathogens, chemical contaminants, or other quality defects. If the affected product is determined to be unsafe or non-compliant, it must be rejected, reworked, or destroyed. Procedures should be implemented to prevent the recurrence of the deviation. This may involve revising procedures, improving training, or implementing new control measures. All corrective actions should be documented in the HACCP recordkeeping system. For example, if the internal temperature of a cooked chicken breast falls below the critical limit of 74°C (165°F), the cooking process should be stopped, the oven temperature should be checked and adjusted, the affected chicken breasts should be held for further cooking or discarded, and procedures should be reviewed to prevent future temperature deviations. This ensures that the HACCP plan is effectively controlling the identified hazards and protecting consumer safety.