1. Introduction

Every food business in the UK must have a HACCP (Hazard Analysis and Critical Control Points) plan to comply with food safety regulations and ensure the food you produce is safe for consumers.  A HACCP plan outlines how your business mitigates the risk of biological, chemical, physical and allergenic food safety hazards in a way that’s easy for staff to follow.  But what does a plan look like? Let’s look at the two primary structures—linear and modular—and list the advantages and disadvantages, so you can decide which is right for your business.

2. Linear HACCP plan

A linear HACCP plan follows a step-by-step approach through the production process. Each step in the production line is analysed sequentially for potential hazards and control measures are implemented accordingly.

Characteristics of a linear HACCP plan:

• Sequential flow: Process is mapped out in a straight line from start to finish.
• Step-by-step hazard analysis: Each stage of the process is examined one after another.
• Single continuous document: Entire plan is typically contained in a single, continuous document.
• Simplicity: Linear pattern makes the plan easier to understand and follow for straightforward processes.
• Singular focus: Given the approach, linear plans are most often used for one product or production line.

Here’s an example of a linear HACCP plan for the production of flapjacks.

Linear plans are product specific. Often adopted for individual products, everything contained in one HACCP study.

Image credit: Food Standards Agency

Advantages of a linear HACCP plan

• Clarity: Clear, straightforward steps make plans easy to follow from start to finish.
• Comprehensiveness: Steps can easily be analysed thoroughly, reducing the risk of potential hazards being missed.

Disadvantages of a linear HACCP plan

• Complexity in diverse operations: Can become unwieldy for operations with multiple products or production lines.
• Lack of flexibility: Less adaptable to changes in the production process or introducing new products.

3. Modular HACCP plan 

A modular HACCP plan breaks down the production process into distinct modules or units. Each module represents a specific part of the production process and each can be analysed independently for hazards and control measures.

Characteristics of a modular HACCP Plan:

• Divided into modules: Process is split into separate units, each dealing with a specific part of the production.
• Independent analysis: Each module is analysed for hazards independently.
• Flexible documentation: Each module in the process can have its own set of documents.
• Adaptability: Separate units allow for changes to plans an application on multiple products or production lines.
• Specialisation: Allows for focused attention on specific areas of the production process.

Here’s an example of a modular HACCP plan for the production of pies.

Modular HACCP Plan are more process specific, this plan could be used for a variety of pies for instance sweet and Savory.

Advantages of a modular HACCP plan

• Flexibility: Easier to modify and adapt when changes occur in the production process than a linear HACCP plan.
• Scalability: Better suited for complex operations with multiple products or production lines.
• Specificity: Can address specific hazards and control measures more precisely within each module.

Disadvantages of a modular HACCP plan

• Complexity management: Multiple products and production lines make it more difficult to ensure consistency across modules.
• Integration: Requires careful integration to ensure that all modules work together seamlessly.

Which HACCP plan should you use?

The right HACCP plan depends on the needs and complexity of your food production operation.  If you have a single-product production process, a step-by-step linear HACCP plan keeps things simple, with everything contained in one study.  If you produce multiple products with different process and production lines, a modular HACCP plan gives you more flexibility and adaptability to be process specific.

Unsure of which option to go for? Get in touch. We’ll review your current set-up and establish the right plan for your requirements.