Introduction
For a Hazard Analysis and Critical Control Point (HACCP) plan to work well, it is important to first identify and understand all possible food safety risks. To help with this key step, we have created several detailed hazard analysis tables that cover a wide range of contaminants.
The information below focuses specifically on physical hazards. These are any foreign objects found in food that are not meant to be there, and they can pose a serious risk of injury to the consumer. The hazard table provided gives a complete overview, showing common sources of these hazards, effective methods for prevention, and listing the important control points and checks needed to manage physical contamination.
Because the table contains a lot of detailed information spread across many columns, it is best to download the file to see it properly.
What are physical hazards?
A physical hazard refers to any foreign material or object in food that can cause illness or injury. Common examples include fragments of glass, metal, plastic, wood, and stones.
These objects can accidentally enter the food supply at any stage of production, from the farm to the processing facility. Sources can include harvesting and processing machinery, packaging materials, the building environment, or even personnel.
To protect consumers, food producers implement a variety of preventive controls. These include advanced detection methods like metal detectors and X-ray scanners, as well as screens, filters, and thorough visual inspections. Strict Good Manufacturing Practices (GMPs) and employee training are also fundamental to prevention. Because of these comprehensive systems, the resulting health risk to the public from physical hazards is significantly minimized.
Sources
Physical Hazards Table
| Component | Origin | Characteristics | Severity | Control | Prevention |
|---|---|---|---|---|---|
| Glass | Raw materials (agricultural, horticultural), packaging materials (jars, bottles), light fixtures, utensils, gauge covers, thermometers. | Sharp, brittle, transparent or colored, various sizes. | Medium to High. Can cause cuts, internal bleeding, dental damage. Small fragments may pose a choking hazard. Consumer aversion, brand damage. | Visual inspection of raw materials and finished products, glass breakage policies, sieves, X-ray inspection, metal detection (for some glass types with metallic content). | Use alternatives to glass where possible (e.g., plastic). Protective coverings for lights. Regular inspection of glass containers. Staff training on handling glass. Keep glass out of production areas. |
| Metal | Machinery (blades, sieves, wires, nuts, bolts), agricultural sources (wire, bullets), packaging (staples, cans), staff (jewelry, pens), cleaning equipment (scourers). | Sharp, hard, various shapes and sizes (fragments, shavings, wires). | Medium to High. Can cause cuts, choking, internal injury, dental damage. Magnetic or non-magnetic. | Metal detectors, X-ray inspection, magnets, sieves, visual inspection. Regular maintenance of equipment. | Proper equipment maintenance and pre-start up checks. Staff training on foreign object control and personal hygiene (no jewelry). Controlled use of staples and metal clips. |
| Wood | Pallets, crates, boxes, field debris, building materials, utensils, cleaning equipment (brushes). | Splintery, various sizes, can be hard or soft. | Low to Medium. Can cause choking, cuts, mouth or throat irritation. May harbor microorganisms. | Visual inspection, sieves, X-ray inspection (density dependent), wood control programs. | Use food-grade plastic or metal pallets/containers. Regular inspection and maintenance of wooden structures and equipment. Avoid using wood in direct food contact areas if possible. |
| Stones/Minerals | Agricultural raw materials (fields, soil), building materials (concrete, pebbles), processing aids. | Hard, various shapes and sizes, abrasive. | Medium. Can cause choking, dental damage, internal injury. | Stone traps, de-stoners, flotation washers, sieves, X-ray inspection, visual inspection. | Sourcing from approved suppliers with good agricultural practices. Effective cleaning of raw materials. Building maintenance to prevent crumbling concrete. |
| Plastic | Packaging materials (films, fragments, ties), equipment (worn parts, utensils), staff (pens, PPE fragments), raw material containers. | Flexible or rigid, various shapes, sizes, and colors. Can be sharp if broken. | Low to Medium. Can cause choking, internal blockage. May leach chemicals. | Visual inspection, sieves, X-ray inspection (density dependent), color sorting equipment. | Use detectable plastics where possible. Proper maintenance of plastic equipment. Control of packaging materials. Staff training on handling plastics. |
| Personal Effects | Staff (jewelry, buttons, pens, hair clips, false nails, band-aids). | Various materials (metal, plastic, fabric, glass), shapes, and sizes. | Low to Medium. Can cause choking, cuts, or internal injury. May introduce microbiological contamination. | Strict personal hygiene policies (e.g., no jewelry, secure band-aids), metal detectors, X-ray inspection. | Staff training and enforcement of GMPs, including policies on jewelry, hair coverings, and personal items in production areas. Use of detectable band-aids. |
| Pests/Insects | Fields, storage areas, processing environment, raw materials. | Whole insects, insect fragments, larvae, eggs, rodent droppings, hair. | Low to High. Can cause disgust, allergic reactions, transmit pathogens, introduce filth. | Pest control programs (traps, bait stations), sieves, filters, visual inspection, insect light traps, fumigation (where appropriate). | Integrated Pest Management (IPM) program, proper sanitation, sealing of building entry points, inspection of incoming raw materials, good storage practices. |
| Bone Fragments | Meat, poultry, fish raw materials. | Hard, sharp, brittle, various sizes. | Medium. Can cause choking, cuts in mouth/throat, internal injury. | X-ray inspection, visual inspection, bone removal systems (e.g., grinders with bone eliminators), sieves. | Sourcing from reputable suppliers with good deboning practices. Careful trimming and inspection of meat/fish. Staff training in handling and processing. |
| Unwanted Natural Components | Raw agricultural materials (e.g., fruit pits/stones, seeds, stems, shells from nuts or seafood, hard pieces of produce). | Hard, potentially sharp, or cause unpleasant texture; varies in size and density depending on the source. | Low to Medium. Can cause choking (especially in children or elderly), dental damage, or discomfort. Reduces product quality and acceptability. | Sorting (manual, mechanical, optical), sieving, destoning/pitting machinery, shelling equipment, X-ray inspection (for denser items like pits), filtration, specific gravity separators. | Sourcing high-quality raw materials with fewer defects. Using specific varieties (e.g., "seedless"). Effective primary processing techniques (e.g., efficient pitting, shelling, destemming). Supplier controls. |
Comprehensive compliance with iMIS Food
Please note that the hazard tables provided here are for informational purposes and serve as a general guide. iMIS Food Compliance offers significantly more detailed and robust hazard analyses that are essential for full regulatory compliance. For more information on our complete food safety solutions or to request a consultation, please get in touch via email or visit the following page
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