10 Things to Know About Color-Coding: Zones and Critical Control Points

Understanding Zones and Critical Control Points in Color-Coding Every food processor knows that meeting food safety regulations from the FDA and other regulatory agencies is essential for the success of their operations. Without compliance, it's nearly impossible to run an effective food processing program. The number of recalled food products continues to grow daily, often due to cross-contamination, which can cost companies millions of dollars. The saying “better safe than sorry” is especially relevant when it comes to avoiding recalls. One simple yet effective method to help keep your food processing operation safe is color-coding. One of the most important FDA guidelines is HACCP. Complying with HACCP regulations is a key part of any food processing operation, and identifying critical zones and preventing cross-contamination is central to this compliance. HACCP procedures are currently in place for dairy, juice, retail seafood, and retail and food service. HACCP stands for Hazard Analysis and Critical Control Points. It is a preventive approach used to identify, evaluate, and control food safety hazards that could cause illness or injury if not properly managed. In short, HACCP helps control the risk of cross-contamination from biological, chemical, and physical agents. According to the FDA, “any action or activity that can be used to prevent, eliminate, or reduce a significant hazard” is considered a control measure. Color-coding is a perfect example of such a measure. Once potential food safety hazards are identified, critical control points can be documented. The FDA defines a critical control point as “a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level.” Understanding where these critical control points exist in a production process is crucial for developing an effective HACCP plan. The FDA provides various resources to help food processors implement HACCP, including a decision tree that aids in identifying critical control points. While using a decision tree isn't mandatory, it's a helpful tool for creating a comprehensive food safety program. Color-coding is often used in areas that correspond to critical control points or groups of them. For example, a specific color might be assigned to an area where raw meat is handled, as it poses a higher risk of bacterial contamination. Within that color zone, there may be multiple control points, such as temperature monitoring or hygiene checks. Once the meat is cooked, a different color is typically used to mark the next area, helping prevent contamination of the final product. This visual system makes it easy to ensure that equipment and tools are used in the correct zone, improving overall safety. With color-coding in place, it’s immediately clear which zones are which and what they represent. This clarity makes it easier to separate contaminated items before they reach consumers. And as we all know, internal recalls—when they happen—are far less expensive than public ones. If you're unsure whether color-coding is suitable for your facility, feel free to download our worksheet below and assess your needs.

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