Improving Food Safety Through the Implementation of Hazard Analysis and Critical Control Points (HACCP) in Conjunction With the Failure Mode and Effects Analysis (FMEA) Model in a Croissant Production Factory in Iran: A Case Study

Abstract

The Hazard Analysis and Critical Control Points (HACCP) is a systematic approach to identifying, assessing, and controlling hazards at all stages of food production. Failure Mode and Effects Analysis (FMEA) is a systematic methodology for enhancing system reliability and operational performance by identifying potential failures in advance. This study aimed to implement the HACCP system and the FMEA model to ensure product safety in croissant production. Primary hazard analysis was used to predict failure modes in the croissant production line based on the functions, properties, and interactions of materials or processes on which the system depends. The identified hazards at each stage were categorized into three categories: chemical, biological, and physical. A process flow diagram was drawn, and Critical Control Points (CCPs) were identified and monitored using the decision tree. The identified CCPs included baking, cocoa injection, metal detection, and packaging. The Risk Priority Number (RPN) ranged from 24 to 240, and the HACCP plan should address the risks with an RPN of above 64. The results of microbial tests (S. aureus, E. coli, Enterobacteriaceae, mold, and yeast) and chemical tests (pH and moisture) indicate that croissants produced at different times comply with the Iranian National Standard Organization (INSO) requirements. Based on the findings of this study, given the high severity of the impact and the irreparability of some errors, it is crucial to predict and control risks during the production and storage stages before the product enters the market.