Free reference
Bakery HACCP hazards by process step
70 hazards across 25 process steps, with the control measure for each. This is the hazard library behind the plans this site produces, published in full.
What are the food safety hazards in a bakery?
A bakery carries biological hazards such as Bacillus cereus and Salmonella in raw ingredients, chemical hazards including mycotoxins in flour, cleaning residue and acrylamide at high bake colour, physical hazards such as wire from a damaged sieve mesh or metal from a worn mixer blade, and allergen hazards from the fourteen regulated allergens.
The 70 hazards below are the ones this site's plans are built from, set against the process steps of a real bakery. They are compiled against Codex Alimentarius CXC 1-1969 (Rev. 2020) and BRCGS Global Standard for Food Safety Issue 9, and every UK food business is required to have procedures based on HACCP principles under assimilated Regulation (EC) No 852/2004, Article 5.
| Type | Count |
|---|---|
| Biological | 36 |
| Physical | 18 |
| Allergen | 9 |
| Chemical | 7 |
| Total across 25 process steps | 70 |
How to use this
Work down your own process and, at each step, ask which of these hazards can occur, whether it is already present, introduced there, able to grow there, or able to survive that step. That last question is the one most small bakeries skip, and it is where the baking and cooling steps trip people up. Baking destroys vegetative pathogens. It does not destroy Bacillus cereus spores, so control passes to how quickly the product cools.
Hazard type is shown as biological, chemical, physical or allergen. PIGS is the standard classification of how the hazard arises at that step: Presence, Introduction, Growth or Survival.
Goods in
Raw materials, packaging and part-baked components are received, checked against the delivery note and specification, and accepted or rejected.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Mycotoxins (deoxynivalenol, ochratoxin A, aflatoxins) present in flour, cereals, dried fruit, nuts or spices as supplied | Chemical | Presence | Purchase to a written specification that states compliance with assimilated Regulation (EC) No 1881/2006 maximum levels. Approved supplier with a current certificate of analysis or an annual mycotoxin surveillance declaration for cereal and dried fruit lines. Reject any delivery without traceable documentation. |
| Foreign body carried into site within raw materials (string, sacking fibre, stones, insect fragments, metal swarf from milling) | Physical | Presence | Visual inspection of every delivery for bag integrity and cleanliness. Damaged or contaminated sacks rejected at the bay. Downstream control by sieving and, where fitted, metal detection. Control transfers to the sieving step. |
| Undeclared or substituted allergen in a supplied ingredient, including cross-contact declared only as a precautionary statement | Allergen | Presence | Signed ingredient specification for every raw material listing all 14 regulated allergens present and any cross-contact risk. Specifications re-confirmed annually and on any supplier or recipe change. Label and specification checked against the delivery at intake. |
| Economically motivated adulteration of a bought-in ingredient (vanilla, honey, olive oil, ground spices, ground nuts) introducing an undeclared substance or a non-permitted colour such as a Sudan dye | Chemical | Presence | Raw materials bought to a written specification from an approved supplier, the specification stating authenticity and compliance with assimilated Regulation (EC) No 1333/2008 on permitted food additives. Materials with a known history of adulteration, being vanilla, honey, olive oil, ground spices and ground nuts, bought only from a supplier holding a recognised certification or supported by a certificate of analysis for the delivered lot. Supplier approval reviewed annually and on any change of source or intermediary. Deliveries without traceable documentation rejected at intake. |
| Pest infestation or mould introduced on damaged, damp or previously infested delivery | Biological | Introduction | Intake inspection of vehicle and outer packaging for damp, gnaw marks, webbing or live insects. Rejection procedure recorded. Pest control contractor notified of any find. |
| Growth of pathogens in chilled or frozen components delivered above specification temperature | Biological | Growth | Probe or infrared temperature check on every chilled and frozen delivery, recorded against a specification of 8 degrees Celsius or below for chilled and minus 18 degrees Celsius or below for frozen. Out-of-specification deliveries rejected. |
Ambient storage
Flour, sugar, dried fruit, fats and packaging are held at ambient temperature on racking clear of the floor and wall, under stock rotation.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Pest infestation of stored flour, dried fruit and nuts leading to contamination of product | Biological | Introduction | Documented pest control contract with routine inspection and a site plan of bait and monitoring points. Materials stored off the floor and away from the wall, sacks closed, spillage cleared immediately. Contractor reports reviewed and actions closed out. |
| Contamination of food-contact packaging held in open or shared storage | Physical | Introduction | Packaging stored covered, off the floor, segregated from raw materials and chemicals. Outer transit wrap removed only at the point of use. |
| Use of ingredients beyond their durability date, giving rancidity in fats or loss of the supplier's mycotoxin and quality assurance | Chemical | Presence | First-in-first-out stock rotation with date-marked and labelled stock. Monthly stock check for out-of-date material. Out-of-date stock quarantined and disposed of against a record. |
Chilled and frozen storage
Dairy, egg, cream, meat and fish components and any frozen part-baked goods are held under temperature control.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of Salmonella spp., Listeria monocytogenes and Staphylococcus aureus in cream, dairy, egg and cooked meat components held above 8 degrees Celsius | Biological | Growth | Chilled storage operated at 5 degrees Celsius or below with a continuous or twice-daily recorded temperature check against a maximum of 8 degrees Celsius. Frozen storage at minus 18 degrees Celsius or below. Documented action on any excursion, including assessment of the affected stock. |
| Cross-contamination of ready-to-eat components from raw meat, fish or shell egg stored above or alongside them | Biological | Introduction | Ready-to-eat components stored above raw components, covered and date labelled. Raw meat and fish held in a dedicated area or on the lowest shelf in sealed containers. |
Thawing and defrosting
Frozen bought-in dough pieces, part-baked product, fruit, purées or dairy are brought up to working temperature before use, under refrigeration or in a controlled thaw cabinet.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of Salmonella, Listeria monocytogenes and other pathogens in dough pieces, dairy or fruit thawed at ambient temperature or over an extended period | Biological | Growth | Frozen materials thawed under refrigeration at 5 degrees Celsius or below, or in a thaw cabinet operating to a written specification. Thawing started and finished within a defined period, with the date and time recorded on the container. Material not returned to the freezer once thawed. |
| Cross-contamination of ready-to-eat product from thaw drip running off raw or unbaked material stored above it | Biological | Introduction | Thawing carried out in covered, lidded containers deep enough to hold the drip. Thawing material stored on the lowest shelf, never above open or ready-to-eat product. Thaw surfaces cleaned and disinfected after every use. |
| Allergen carry-over from uncovered thawing of an allergen-containing material beside or above material for a product that does not declare it | Allergen | Introduction | Every thawing container covered and labelled with the material and its allergens. Allergen-containing materials thawed in a separate, identified location or at a separate time, with a documented clean-down between. |
Sieving and screening
Flour and other dry ingredients are passed through a sieve or rotary screen of defined aperture before use, and the tailings are inspected.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Foreign body present in dry ingredients (string, sacking fibre, stones, insect debris, metal swarf) passing forward into the dough | Physical | Presence | All dry ingredients passed through a sieve or rotary screen of defined aperture. Tailings inspected and the finding recorded at the end of every sieving session. Any significant find investigated and the supplier notified. |
| Wire or mesh fragment introduced into product by a damaged, holed or distorted sieve screen | Physical | Introduction | Sieve mesh condition checked and recorded before and after every sieving session. Any damaged screen removed from service immediately, all product sieved since the last good check quarantined, and the screen replaced against a record. |
Weighing and scaling
Ingredients are weighed to the recipe on calibrated scales and staged for the mixer.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Incorrect allergen-containing ingredient picked or weighed into a recipe, giving an undeclared allergen in the finished product | Allergen | Introduction | Ingredients decanted into labelled, colour-coded and lidded containers. Recipe followed from a controlled written specification with a second-person check on allergen-containing additions. Decanted containers never topped up with a different material. |
| Chemical contamination of ingredients from cleaning chemical residue on scales, scoops or containers | Chemical | Introduction | Cleaning chemicals stored in a locked or segregated store away from ingredients, used to a written dilution and rinse instruction, and never decanted into unlabelled containers. Food-contact surfaces rinsed and dried before use. |
| Overdosing of a functional additive with a regulatory maximum, for example a preservative or raising agent, through inaccurate weighing | Chemical | Introduction | Scales calibrated at a defined frequency against traceable test weights, with a daily accuracy check recorded before production. |
Mixing
Ingredients are combined with water in a spiral, planetary or horizontal mixer to a defined time, speed and final dough or batter temperature.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Metal fragment from a worn or damaged mixer blade, bowl, bowl scraper or spiral hook entering the dough | Physical | Introduction | Documented inspection of mixer bowl, blade, hook and scraper for wear, cracking and missing material at the start and end of every production day. Damaged equipment removed from service. Planned preventive maintenance with a record of every part changed. Control transfers to the metal detection step. |
| Hard plastic fragment from a scoop, jug, scraper or lid entering the dough | Physical | Introduction | Glass and hard plastic register listing every item in the production area, with a scheduled condition check. Brittle plastic utensils replaced with a detectable or metal alternative where practicable. Breakage procedure requiring the area to be cleared and product quarantined. |
| Allergen cross-contact carried from a previous batch on shared mixer bowls, hooks and utensils | Allergen | Introduction | Production sequenced so that allergen-free products run first after a full clean. Full documented wet clean-down of bowls, hooks, scrapers and surrounding surfaces between allergen and non-allergen batches, verified by visual inspection and recorded. |
| Microbiological or chemical contamination of product from the water supply used in the dough | Biological | Introduction | Mains potable supply. Annual potable water analysis to the Water Supply (Water Quality) Regulations parameters at a point of use, with any internal storage tank inspected and cleaned to a schedule. |
Bulk fermentation
Dough is rested in bulk in covered tubs or a controlled prover to develop flavour and structure before dividing.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of spoilage organisms and wild yeasts in dough held in bulk beyond the intended time | Biological | Growth | Defined bulk fermentation time and temperature per recipe. Dough tubs covered and identified with the time the batch was mixed. |
| Environmental contamination of open dough from overhead structures, lighting or personnel | Physical | Introduction | Dough covered while resting. Overhead fittings and lights shielded or shatterproof and listed on the glass and hard plastic register. Personal hygiene rules covering hair, jewellery and protective clothing. |
Dividing and moulding
Dough is divided to weight, rounded, moulded or deposited into tins, cases or onto trays.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Metal or hard plastic fragment from divider knives, moulder belts, tins or cases entering the product | Physical | Introduction | Start and end of shift inspection of divider, moulder and tins for damage, wear and missing parts. Damaged tins with flaking non-stick coating withdrawn from use. Findings recorded. Control transfers to the metal detection step. |
| Contamination of dough with non-food-grade lubricant from divider or moulder bearings | Chemical | Introduction | Food-grade lubricant only on any equipment above or in contact with open product, controlled through the chemical register and applied to a maintenance schedule. |
Retarding (controlled cold proving)
Divided and moulded dough is held under refrigeration, usually overnight, to slow fermentation and develop flavour before proving and baking.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of Listeria monocytogenes and psychrotrophic pathogens in dough held for an extended period in a retarder running above its set point | Biological | Growth | Retarder operated at 5 degrees Celsius or below against a written specification, with the temperature recorded at the start and end of every retard cycle. Maximum retard time defined per product. Documented action on any excursion, including assessment of the affected dough. |
| Condensate or ice from the retarder evaporator dripping onto uncovered dough below it | Physical | Introduction | Dough covered while retarding. Evaporators sited away from the dough beneath them and inspected as part of planned maintenance. Defrost cycles set so that condensate drains rather than accumulates. Any dripping unit taken out of use until repaired. |
Proving
Moulded pieces are held in a humidified prover at a controlled temperature until the required volume is reached.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of spoilage organisms in dough held in a warm, humid prover beyond the intended time | Biological | Growth | Defined prove time and temperature per product. Prover temperature and humidity checked and recorded daily. |
| Contamination of open dough by condensate dripping from prover ceiling, ducting or trolleys | Biological | Introduction | Prover ceiling, ducting and door seals inspected daily for condensate build-up and mould growth, and cleaned to a documented schedule. Product not left under a known drip point. |
Glazing and egg wash
Egg wash, milk wash, water spray or seed and sugar toppings are applied to the surface of the product before it enters the oven.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Survival of Salmonella from raw shell egg wash on a lightly baked surface, or on product glazed after baking | Biological | Survival | Pasteurised liquid egg used for all glazing in preference to raw shell egg. Glaze applied before baking only. Glaze made up in small quantities, held at 5 degrees Celsius or below, discarded at the end of the session and never topped up. |
| Egg, milk or sesame applied at glazing but not carried through to the product specification and label | Allergen | Introduction | The glaze and every topping treated as an ingredient of the product and recorded on the specification. Label checked against the specification whenever a glaze or topping changes. Seeded and unseeded products of the same shape given distinct labels. |
| Bristles or fragments from a worn glazing brush transferred onto the product surface | Physical | Introduction | Single-piece brushes with bonded heads, or silicone brushes, inspected before and after every use and replaced at the first sign of loss. Brushes recorded on the equipment register. Any brush found damaged triggers examination of the product made since the last check. |
Baking
Product is baked in a deck, rack or tunnel oven to a validated time and temperature schedule.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Survival of Salmonella spp. and other vegetative pathogens present in raw flour, shell or liquid egg, and dried fruit | Biological | Survival | Validated bake schedule delivering a core temperature and hold time proven to achieve the required log reduction for each product. Oven time and temperature set and confirmed for every batch and the result recorded. |
| Survival of Bacillus cereus spores through the bake | Biological | Survival | Spores are not eliminated by a normal bake. Control is transferred to the cooling step, where the rate of cooling prevents germination and outgrowth to an infective dose. Control transfers to the cooling step. |
| Formation of acrylamide during baking of cereal-based products, particularly at high bake colour | Chemical | Introduction | Mitigation measures applied in line with assimilated Regulation (EU) 2017/2158: bake to the lightest acceptable colour, control asparagine through flour selection where practicable, avoid over-baking, and hold a reference colour photograph for each product. Mitigation measures recorded and reviewed. |
| Foreign body from oven fabric, baking sheets or steam ducting falling onto product during the bake | Physical | Introduction | Oven interior, deck stones, chains and steam ducting inspected on the maintenance schedule and after any breakdown. Damaged baking sheets and liners withdrawn. |
Depanning
Product is removed from tins, trays, hoops or cases, by hand or by depanner, while it is still hot, so that it can cool with air moving round it. The empties are returned for cleaning.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Flaking silicone or non-stick tin coating adhering to the product surface during depanning | Physical | Introduction | Tins and trays inspected on a rotating schedule for coating breakdown. Tins withdrawn from use once coating loss is visible and recoated or scrapped against a record. |
| Recontamination of baked product by hand contact after the kill step | Biological | Introduction | Documented personal hygiene rules covering hand washing at entry and after any break or task change, exclusion of staff with diarrhoea or vomiting for 48 hours after symptoms cease, coverage of cuts with a detectable dressing, and no jewellery. |
Cooling
Baked product is cooled on racks, in a spiral cooler or in a blast chiller until it is stable enough to handle, pack or fill.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Germination and outgrowth of Bacillus cereus from spores surviving the bake, producing heat-stable emetic toxin during slow cooling through 50 to 15 degrees Celsius | Biological | Growth | Product cooled through the critical range without delay, on open racking with free air movement or in a blast chiller, to a defined maximum cooling time. Cooling start and finish time recorded for high-moisture and filled products. |
| Recontamination of the cooling product with airborne mould spores, yeasts and bacteria from the cooling environment, shortening shelf life and giving visible mould | Biological | Introduction | Cooling area kept clean and dry with a documented cleaning schedule covering racks, floors and overhead surfaces. Filters on any cooling air supply changed to a schedule. Cooling area kept free of flour dust and waste. Traffic through the area minimised. |
| Foreign body contamination of open cooling product from rack wheels, overhead structures, flaking paint or personnel | Physical | Introduction | Overhead structures above cooling product inspected on the maintenance schedule. Racks maintained in good condition. Personal hygiene rules applied in the cooling area as an open-product area. |
Filling and topping preparation
Crème pâtissière, custards, fruit fillings, caramel, buttercream or ganache are cooked or assembled on site, then cooled and held before use.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Germination and growth of Bacillus cereus, with production of a heat-stable emetic toxin, in cooked starch-based fillings such as creme patissiere held warm or cooled slowly | Biological | Growth | Cooked fillings cooled from 63 to 8 degrees Celsius within 90 minutes, in shallow trays no deeper than 50 millimetres or by blast chiller, and never left to cool at ambient overnight. Cooling start and finish times and the final temperature recorded for every batch. Filling used within a defined life and never re-boiled to extend it. |
| Salmonella present in unpasteurised shell egg used in custards, buttercreams and uncooked fillings | Biological | Presence | Pasteurised liquid egg specified for every filling that is not subsequently cooked to a validated time and temperature. Where shell egg is used, the filling is cooked to at least 75 degrees Celsius for 30 seconds and the temperature is recorded. |
| Staphylococcus aureus introduced by hand contact into a ready-to-eat filling that is then held at ambient temperature | Biological | Introduction | Fillings handled with clean utensils rather than hands wherever practicable. Hand washing and disposable glove use at every entry to the filling area, with gloves changed between tasks. Prepared fillings returned to refrigeration immediately and held at 5 degrees Celsius or below. |
Filling and decorating
Cooled product is filled, iced, creamed or decorated by hand or by depositor. This step is downstream of the bake and is therefore an open-product step.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Recontamination of product with vegetative pathogens after the bake, through hands, utensils, depositors and piping bags | Biological | Introduction | Filling and decorating carried out in a designated area treated as high-care for open ready-to-eat product. Single-use or fully cleaned piping bags and nozzles. Documented cleaning schedule for depositors, hoppers and utensils with a validated frequency. Personal hygiene rules enforced. |
| Growth of Staphylococcus aureus, Listeria monocytogenes and Salmonella spp. in fresh cream and fresh dairy fillings held out of temperature control during and after filling | Biological | Growth | Fresh cream and dairy fillings drawn from chilled storage in working quantities only, returned to chill within a defined maximum time out of refrigeration, and the filled product returned to 5 degrees Celsius or below without delay. Time out of chill recorded. |
| Allergen cross-contact at the open product stage from shared nozzles, dusting sugar, nut decorations and airborne particulates | Allergen | Introduction | Allergen-containing decorations handled last in the production sequence or on dedicated equipment. Nut and sesame decorations stored and handled in a segregated area with dedicated utensils. Full clean-down between allergen and non-allergen decorating runs, recorded. |
| Salmonella or other pathogens surviving in a low moisture ingredient added after the bake, such as nuts, desiccated coconut, dried fruit, seeds, chocolate or ground spice | Biological | Presence | Ingredients added after the bake are bought to a written specification from an approved supplier, the specification stating that the material has received a validated pathogen reduction treatment or is supported by a certificate of analysis for the delivered lot. No thermal process after this point reduces the hazard, and pathogens in a low moisture matrix are substantially more heat resistant than in a wet one, so the control rests entirely on the specification. Stored closed, in date and segregated from open product. |
Rework
Misshapes, trimmings, offcuts and short-weight product are returned into a later batch of the same or a compatible recipe.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Allergen carried into a product that does not declare it, by returning rework from an allergen-containing recipe into a different batch | Allergen | Introduction | Rework returned only into the same recipe, or into a recipe that already declares every allergen the rework contains. Every rework container labelled with the product it came from, its allergens and the date. Rework of an allergen-containing product never held in an unlabelled or communal bin. A second person confirms the rework addition against the recipe. |
| Growth of pathogens or moulds in rework held at ambient temperature for too long before it is returned to a batch | Biological | Growth | Rework held in covered, labelled containers, refrigerated where the product supports growth, and used within a defined period from the date on the label. Rework not used is disposed of against a record. Rework never accumulated across more than one production day. |
| Foreign body introduced with rework collected from the floor, from under equipment or from an open container in the production area | Physical | Introduction | Rework taken only from clean, covered containers at the point of production. Product that has touched the floor is waste and is never reworked. Rework passed through sieving or metal detection where the process allows, and the point at which it re-enters the flow is defined in this plan. |
Slicing and portioning
Product is sliced on a reciprocating or band slicer before packing.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Metal fragment from a chipped, cracked or broken slicer blade entering the product | Physical | Introduction | Slicer blades inspected for damage at the start and end of every run and the condition recorded. Blade change procedure requiring all product sliced since the last good check to be quarantined if damage is found. Downstream metal detection where fitted. Control transfers to the metal detection step. |
| Recontamination of the cut surface with moulds and bacteria from soiled blades, guides and crumb trays | Biological | Introduction | Slicer stripped, cleaned and sanitised to a documented schedule and at the end of every production day. Crumb build-up removed between runs. Cleaning verified by inspection and recorded. |
Metal detection
Packed or unpacked product passes through an in-line metal detector or X-ray unit fitted with an automatic reject device and reject confirmation.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Failure to detect or reject ferrous, non-ferrous or stainless steel contamination carried forward from earlier steps | Physical | Presence | Every unit of product passed through a metal detector or X-ray unit with an automatic reject device. Detector challenged with certified test pieces to a defined frequency, with reject confirmation on each check. |
Packing
Product is bagged, flow-wrapped, boxed or placed in trays and sealed.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Foreign body or contamination introduced by packaging materials, including transit wrap, staples and cardboard fibre | Physical | Introduction | Packaging held in a clean, segregated store and de-wrapped outside the packing area. Food-contact packaging purchased to specification with a declaration of compliance for food contact use. |
| Recontamination and shortened shelf life through poor bag or wrap seal integrity | Biological | Introduction | Seal integrity checked at start-up and at a defined frequency through the run. Sealing jaw temperature monitored where a heat seal is used. |
Labelling and coding
The correct label carrying the ingredient declaration, allergen emphasis and durability date is applied and verified against the product specification.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Incorrect label applied to the product, giving an incorrect or missing allergen declaration for the food in the pack | Allergen | Introduction | Label reconciliation at the start of every run: the label on the line is checked against the controlled product specification by a named person before packing begins, and at every product changeover. Obsolete labels removed from the line and destroyed. Check recorded and signed. |
| A free-from claim carried on the label that the process cannot support, for example gluten-free product made on shared equipment | Allergen | Presence | Any free-from claim supported by a documented validation: segregation or validated clean-down, ingredient specifications confirming absence, and analytical verification at a defined frequency. Gluten-free claims supported against the 20 mg/kg threshold in assimilated Regulation (EU) No 828/2014. |
| Missing or incorrect durability date, allowing product to be sold beyond the validated shelf life | Biological | Growth | Date coding set and verified at the start of every run against the shelf life stated in the product specification. Shelf life supported by documented shelf life trials or a scientific rationale. |
| Salmonella or Shiga toxin-producing E. coli in flour or shell egg that is sold without a lethal step, for example a raw dough product, an unbaked biscuit base, a raw-egg buttercream or mousse, or flour dusted onto finished product | Biological | Presence | No product is sold containing flour or shell egg that has not passed through a validated lethal step. Where a product requires either without baking, heat treated flour and pasteurised egg are used and the specification records it. Flour used for dusting is applied before the bake, never to finished product. |
Freezing and frozen finished goods storage
Finished product is blast frozen or frozen down and held below minus 18 degrees Celsius until it is ordered and despatched.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of pathogens in the centre of product frozen slowly because warm product was stacked tightly or the freezer was overloaded | Biological | Growth | Product cooled to ambient before it enters the freezer. Loads spaced so that air circulates, and the freezer not loaded beyond its rated capacity. Product core confirmed to be below minus 18 degrees Celsius before it is moved to frozen storage, and the reading recorded. |
| Partial thaw and refreezing of finished goods following a freezer failure or a door left open, giving growth and a loss of the frozen shelf life | Biological | Growth | Frozen store fitted with a temperature record and an out-of-hours alarm. Temperature checked and recorded at least daily. Documented action on any excursion, including assessment and, where the product has thawed, its disposal against a record. |
| Packaging split or made brittle by freezing, exposing the product to contamination in the frozen store | Physical | Introduction | Packaging specified as suitable for frozen storage and confirmed with the supplier. Packs inspected on entering and leaving the freezer. Damaged packs removed and the product assessed rather than re-wrapped and returned to stock. |
Finished goods storage
Labelled product is held in ambient, chilled or frozen finished goods storage pending despatch, under stock rotation.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of pathogens in chilled finished product held above 8 degrees Celsius in finished goods storage | Biological | Growth | Chilled finished goods held at 5 degrees Celsius or below, monitored and recorded at least twice daily, with a documented action on excursion. |
| Mould growth and pest access to packed finished goods in storage | Biological | Introduction | Finished goods stored off the floor in a clean, dry, pest-monitored area under first-in-first-out rotation, with damaged packs withdrawn. |
Despatch
Finished goods are picked, checked against the order and loaded into a clean vehicle at the correct temperature for delivery.
| Hazard | Type | PIGS | Control measure |
|---|---|---|---|
| Growth of pathogens in chilled product through temperature abuse in transit | Biological | Growth | Vehicle pre-cooled before loading. Product temperature checked and recorded at load. Chilled deliveries carried at 8 degrees Celsius or below in a refrigerated or insulated vehicle, with journey times defined. |
| Contamination of product from an unclean or inappropriately shared delivery vehicle | Biological | Introduction | Vehicle load area inspected for cleanliness, odour, damage and previous load before every load, and the check recorded. Vehicle cleaning schedule in place. Food carried separately from non-food loads. |
| Inability to trace and recall affected product following a food safety incident | Biological | Presence | Batch or date code recorded against every customer despatch. Traceability exercise carried out at least annually, forward and backward, and completed within four hours. Documented product withdrawal and recall procedure. |
Questions bakers ask about these hazards
What are the food safety hazards in a bakery?
A bakery carries biological hazards such as Bacillus cereus and Salmonella in raw ingredients, chemical hazards including mycotoxins in flour, cleaning chemical residue and acrylamide at high bake colour, physical hazards such as wire from a damaged sieve mesh or metal from a worn mixer blade, and allergen hazards from the fourteen regulated allergens.
Does baking kill all bacteria in bread and cakes?
No. Baking reliably destroys vegetative pathogens such as Salmonella and E. coli, because the core of the product reaches a lethal temperature. It does not destroy Bacillus cereus spores, which survive the bake and can germinate as the product cools. That is why cooling is a control point in its own right and not simply the end of baking.
Why is Bacillus cereus a problem in baking?
Its spores survive the bake, and a dense, high-moisture product cooling slowly overnight sits in the temperature range where they germinate and multiply. Some strains then produce an emetic toxin, and that toxin is heat stable: once it is in the product, reheating will not make it safe. The control is how quickly the product cools, because nothing after that point removes the hazard.
What are the critical control points in a bakery?
Most craft and wholesale bakeries end up with four or five: the bake, the cool, metal detection where a detector is fitted, allergen labelling, and the filling step where fresh cream or fresh dairy is used. Which of those apply depends on the products and the process, and each has to be worked through a decision tree rather than assumed.
What is PIGS in hazard analysis?
PIGS is how a hazard arises at a given process step: Presence, meaning it is already in the material arriving; Introduction, meaning the step brings it in; Growth, meaning the step lets it multiply; and Survival, meaning it lives through a step intended to remove it. Asking which applies at each step is what stops a hazard analysis becoming a list.
Do I need metal detection in a bakery?
It is not a legal requirement, and many craft bakeries do not have one. Without it, foreign body control rests entirely on the upstream measures: sieving every dry ingredient through a defined aperture, checking the mesh before and after every session, and inspecting equipment for damage. Those records become the evidence an auditor asks for instead.
Turning this into a plan
A hazard list is not a HACCP plan. The plan is what you build on top: which of these hazards are significant for your products, which steps are critical control points, what the measurable limit is at each one, who checks it and how often, and what happens when a check fails.
You can do that yourself with the free FSA MyHACCP tool, or compare the five ways of getting a plan. This site will do it from about 25 questions for £49. There is a complete worked example you can read first, with no email address needed.