Introduction to physical hazards
Several HACCP hazard tables are available, below you will see the HACCP hazard table we have made concerning the subject: Physical hazards. Because this table is very extensive, we recommend using the download below to view the table properly.
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. |
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