Hazard Analysis Tips
Practical guidance for HACCP-style risk assessment in South African food & feed manufacturing.
Understanding Hazard Analysis in Feed and Food Safety Systems
A hazard analysis is the foundation of every effective Feed or Food Safety Management System. It identifies what could go wrong, how severe the outcome could be, and how the company prevents those hazards from reaching the product or the consumer.
At JDVQ Consultants, our hazard analysis model is built on internationally recognised standards — ISO 22000:2018, GMP+ FSA Module B1, and Codex HACCP Principles — but adapted to the realities of South African feed and ingredient manufacturing environments.
We design templates that help companies apply the same logic auditors use during certification assessments — traceable, structured, and defensible.
What the Hazard Analysis Does
The hazard analysis systematically evaluates each stage of your operation — from raw material intake to final product dispatch — to determine:
• Which hazards are possible (biological, chemical, physical, or allergenic),
• How and when they could enter the process,
• What control measures already exist (PRPs or OPRPs),
• How effective those controls are, and
• Whether additional controls are required.
Your hazard analysis is the “map” that connects your PRPs (e.g., sanitation, supplier approval, pest control) with your process flow and risk management decisions. When completed correctly, it’s also your best audit defence tool — it shows the assessor that you understand your process risks better than anyone else.
JDVQ Hazard Analysis Framework
Every JDVQ hazard analysis template follows a structured format used by leading certification bodies:
Process Step — Describes the exact point in production (e.g. “Mixing,” “Packing,” “Loading”).
Potential Hazard — Lists possible hazards (microbial contamination, cross-contact, foreign matter, etc.).
Hazard Type — Classified as Biological, Chemical, Physical, or Allergenic.
Likelihood (L) — Probability of occurrence rated 1–5.
Severity (S) — Consequence of occurrence rated 1–5.
Risk Rating (L × S) — Calculated risk value used for prioritisation.
Existing Control Measures — Preventive actions already in place (e.g. supplier COA, sieving, sanitation).
Additional Actions Required — Improvements needed if risk is Medium or High.
Verification / Monitoring — How the effectiveness of each control is confirmed (e.g. testing, audits).
This approach allows an auditor to follow the logic of your risk decisions line by line — no guessing, no vague justifications.
Example of an Extracted Hazard Analysis
Process Step
Potential Hazard
Type
L
S
Risk Rating
Existing Controls
Verification
Raw Material Intake
Mycotoxin contamination in maize meal
Chemical
3
5
15 (High)
Purchase only from GMP-approved suppliers; COA required; incoming sampling and testing.
Supplier audits; COA review; trend analysis of test results.
Mixing
Cross-contamination between batches
Biological / Allergenic
2
4
8 (Medium)
Sanitation between batches; allergen scheduling.
Visual inspection; sanitation records; verification swabs.
Liquid Addition
Incorrect dosage of organic acid
Chemical
2
3
6 (Medium)
Calibrated dosing pumps; batch verification sheets.
Calibration records; QA review of batch reports.
Packing
Metal fragments from equipment wear
Physical
2
5
10 (Medium)
Metal detector on packing line; magnet checks during blending.
Detector calibration logs; magnet inspection forms.
Dispatch
Damaged bags during loading
Physical
1
3
3 (Low)
Visual checks before loading; forklift operator training.
Dispatch inspection record; corrective action form.
Risk Rating Interpretation Guide
Risk Level
Rating Range (L×S)
Action Required
Low
1–5
Acceptable risk. Manage through routine PRPs.
Medium
6–10
Additional control or monitoring may be needed. Verify PRPs’ effectiveness.
High
11–15
Immediate corrective or preventive action required. Document justification and verification plan.
Our templates automatically calculate and colour-code risk levels to simplify review and ensure consistency across departments.
Common Mistakes in Hazard Analysis (and How JDVQ Templates Prevent Them)
❌ Listing generic hazards that do not apply to the process.
✅ JDVQ templates provide realistic examples aligned with your scope and product type.
❌ Missing hazard justification or unclear risk ratings.
✅ Each risk decision includes guidance text and sample reasoning for auditors to follow.
❌ Mixing PRPs, OPRPs, and CCPs incorrectly.
✅ JDVQ’s integrated approach removes unnecessary CCPs and uses realistic PRP verification logic consistent with GMP+ FSA B1.
❌ Hazard analysis not linked to the process flow diagram.
✅ Our templates include a ready-to-use Process Flow Mapping Sheet that links each step to the corresponding hazard analysis row.
What’s Included in the JDVQ Hazard Analysis Template Kit
✅ Editable Excel-based Hazard Analysis Sheet with automated risk scoring and filters.
✅ Example hazard library (feed, food, additive, blending environments).
✅ Colour-coded Risk Matrix and interpretation guide.
✅ Cross-linked PRP and Verification register samples.
✅ Review checklist for annual updates and verification sign-off.
In Summary
A well-built hazard analysis isn’t just an audit requirement — it’s the backbone of your food or feed safety management system.
The JDVQ Hazard Analysis Template gives your team the confidence to conduct risk assessments that stand up to audit scrutiny, improve traceability, and cut down on paperwork fatigue.
