HACCP Plan Template – Central Kitchen (Cook-Chill)
Cook-chill is a brilliant system until the chill step underperforms – then you’ve cooked food for bacteria. This plan treats blast-chilling as the star CCP it is, with regeneration at the satellites closing the loop.
We’ve seen this used well: the team prints it, walks the plant with it, and argues about it. Fill in your [bracketed] details, challenge anything that doesn’t match your process, and don’t sign off until you’d defend every line to an auditor.
1. Document control
| Field | Details |
|---|---|
| Document title | HACCP Plan Template – Central Kitchen (Cook-Chill) |
| Document no. | [QA-HACCP-024] |
| Version | [1.0] |
| Effective date | [YYYY-MM-DD] |
| Prepared by | [Name / Title / Date] |
| Approved by | [Name / Title / Date] |
| Review date | [YYYY-MM-DD] |
2. Product description
| Item | Description |
|---|---|
| Product name | [e.g., Cook-chill menu items – attach] |
| Description | [Bulk-cooked, blast-chilled meals for satellite regeneration] |
| Ingredients | [Per recipe – attach] |
| Packaging | [Gastronorm trays, lidded and labelled] |
| Shelf life | [e.g., 5 days at ≤5 °C including regeneration day] |
| Distribution | [Chilled transport to [satellite outlets]] |
3. Intended use and consumers
- General public at satellite outlets.
4. Process flow diagram
Codex Step 5, and the one teams skip: walk the flow on the floor and fix the diagram until it matches what actually happens – including the unofficial shortcuts. Number the final version.
- Receiving
- Storage
- Preparation
- Cooking
- Blast chilling
- Portioning / packing
- Chilled storage (≤5 °C)
- Dispatch to satellites
- Satellite cold storage
- Regeneration
- Service
5. Hazard analysis (Codex Principle 1)
Be honest here. If a hazard is reasonably likely, say so – auditors distrust a hazard analysis where nothing comes out significant. Only significant hazards go to the decision tree.
| Process step | Hazard (B / C / P) | Significant? Rationale | Control measure |
|---|---|---|---|
| Receiving / storage | B: pathogens; cross-contamination | Y | Approved suppliers; ≤5 °C; segregation |
| Cooking | B: survival of pathogens | Y – CCP | Cook to CCP 1 limits |
| Blast chilling | B: C. perfringens growth during slow chill | Y – CCP | Chill to CCP 2 limit (blast chiller validated) |
| Portioning / packing | B: L. monocytogenes cross-contamination | Y | Hygienic handling; time limits; date labelling |
| Dispatch / satellite storage | B: growth if cold chain broken | Y | ≤5 °C; transport checks; satellite temp logs |
| Regeneration | B: survival if inadequately regenerated | Y – CCP | Regenerate to CCP 3 limit; single regeneration |
6. CCPs, critical limits and monitoring (Principles 2-4)
These limits are solid starting points from industry practice and regulation, but they’re not yours yet. Validate each one on your equipment – this is the section auditors probe hardest.
| CCP | Significant hazard | Critical limit | Monitoring (what / how / frequency / who) | Corrective action | Verification | Records |
|---|---|---|---|---|---|---|
| CCP 1 – Cooking | Survival of pathogens | Poultry ≥74 °C; minced meat ≥71 °C; [per recipe] | Probe each batch; [role] | Continue cooking; do not chill undercooked food | Record review; calibration | Cooking log |
| CCP 2 – Blast chilling | Growth of C. perfringens | 90 °C to 3 °C within 90 min [or your validated cycle]; then ≤5 °C | Chiller probe cycle printout each batch; [role] | Re-chill immediately if safe per procedure, else discard; investigate chiller | Record review; chiller validation [annually] | Chill log |
| CCP 3 – Regeneration | Survival of pathogens | ≥74 °C throughout; serve within [time] | Probe each batch at satellites; [role] | Continue regenerating or discard | Record review; calibration | Regeneration log |
7. Corrective action procedure (Principle 5)
- Hold and segregate all product made since the last acceptable check; tag it and enter it in the hold log.
- Restore control (re-cook, adjust temperature, repair equipment) and confirm it before restarting.
- [QA Manager / designee] assesses the affected product – release, rework or disposal – and records the justification.
- Find and fix the root cause; record the deviation, investigation and disposition, signed within [1 working day].
8. Verification procedures (Principle 6)
- A trained reviewer checks CCP monitoring and corrective action records at [frequency, e.g., within 7 days].
- Calibrate monitoring instruments per the calibration schedule.
- Periodic product testing (microbiological, chemical or physical) per the verification schedule.
- Internal audit at least [annually]; full HACCP reassessment annually or after any significant change.
9. Record-keeping (Principle 7)
- Hazard analysis worksheet and CCP decision records
- CCP monitoring records, signed and dated
- Deviation and corrective action records
- Verification records, including calibration
- Training records for the HACCP team and CCP monitors
Approval and control
| Role | Name | Signature | Date |
|---|---|---|---|
| Prepared by | [Name] | [Signature] | [Date] |
| Reviewed by (QA) | [Name] | [Signature] | [Date] |
| Approved by | [Name] | [Signature] | [Date] |
Keep completed forms for [Define retention period, e.g., 2 years beyond shelf life] at [defined location] – and make sure someone besides you knows where that is.