📋 Free HACCP Plan Checklist

Use this checklist to audit your sauce manufacturing HACCP plan. Covers all 7 principles.
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HACCP Plan Checklist — Sauce Manufacturing

A comprehensive audit tool aligned with FDA 21 CFR Part 117. Check each item to verify your HACCP plan is complete.

1. Prerequisite Programs (Foundation)

Written sanitation SOPs for all production areas

Pest control program with documented monitoring

Employee hygiene and health policy (documented and trained)

Approved supplier list with current contact information

Equipment preventive maintenance schedule

Water quality testing results on file (if using municipal or well water)

Allergen control program (if processing multiple products)

Traceability system: one step forward, one step back

2. Hazard Analysis (Principle 1)

Complete process flow diagram from receiving to shipping

On-site verification of flow diagram accuracy

Biological hazards identified for each step (pathogens, spoilage organisms, toxins)

Chemical hazards identified (pesticides, cleaning residues, allergens, mycotoxins)

Physical hazards identified (metal, glass, stones, plastic, wood)

Each hazard assessed for severity and likelihood

Sauce-specific hazards evaluated (C. botulinum in low-acid, allergens in soy/fish sauces)

Hazard analysis signed by PCQI or qualified individual

3. Critical Control Points (Principle 2)

CCP Decision Tree applied to each significant hazard at each step

CCPs clearly distinguished from Control Points and oPRPs

Thermal processing (cooking/pasteurization) evaluated as potential CCP

pH adjustment/acidification evaluated as potential CCP (target ≤ 4.6 for acidified sauces)

Metal detection after packaging evaluated as potential CCP

Allergen segregation points evaluated (if applicable)

Refrigerated storage temperature evaluated as potential CCP

Total CCPs: 2–5 (too many = plan loses focus)

4. Critical Limits (Principle 3)

Each CCP has at least one measurable critical limit

Temperature limits specified in °F/°C with minimum values

Time limits specified (cook time, hold time, cooling time)

pH limits specified with method (calibrated meter, not test strips)

Water activity (aw) limits specified where applicable (≤ 0.85 for shelf-stable)

Metal detector sensitivity specified (Fe 1.5mm, Non-Fe 2.0mm, SS 2.5mm)

Critical limits validated with scientific or regulatory references

5. Monitoring Procedures (Principle 4)

Written monitoring procedure for each CCP

WHAT: The specific measurement defined (temperature, pH, visual check)

HOW: Instrument specified with ID number (Calibrated Thermometer #T-042)

WHEN: Frequency specified (every batch, every hour, start/middle/end of run)

WHO: Monitoring person identified by job title (not name)

Designated monitoring form for each CCP with date and signature lines

Monitoring can detect loss of control in time for corrective action

6. Corrective Actions (Principle 5)

Written corrective action procedure for each CCP deviation

Procedure identifies who is responsible for corrective actions

Specifies how affected product is identified and isolated

Defines root cause investigation process

Specifies product disposition (reprocess / destroy / release after investigation)

Designated corrective action form (Form DEV-01 or equivalent)

Process to prevent recurrence is part of corrective action

7. Verification (Principle 6)

Calibration schedule for all CCP monitoring instruments

Calibration records maintained and current

CCP monitoring records reviewed by supervisor within 7 days

HACCP plan reassessed at least annually

Reassessment triggered by: new ingredient, new equipment, new process, new regulation

Product testing: quarterly microbiological or chemical verification

Third-party audit of HACCP system (annual minimum)

8. Record-Keeping (Principle 7)

HACCP Plan master document with all hazard analyses and CCP determinations

Daily CCP monitoring logs: signed, dated, complete (no gaps, no pre-filled values)

Corrective action records for every deviation

Calibration logs for all CCP instruments

Training records: each monitoring person trained on their specific CCPs

Record retention: 2 years minimum (1 year on-site for non-refrigerated)

Records are contemporaneous (recorded at time of observation, not later)

9. Recall & Traceability

Written recall plan (required under FDA 21 CFR Part 117)

Recall team identified with contact information

Distribution records enable one-step-forward traceability

Ingredient lot tracking enables one-step-back traceability

Mock recall conducted and documented (annual recommendation)

Auditor: _________________________

Date: _________________________

Facility: _________________________

This checklist is provided as a free educational tool by Sauce SOP (saucesop.com). It is not a substitute for professional HACCP plan review by a PCQI. Free to use, print, and share. Version: July 2026.