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HACCP management just got easier

07 May 2016

How do you currently manage your HACCP processes? It could be about to get a lot easier following the introduction of a new solution. 

Testo has recently introduced a new HACCP management system aimed at the food processing industry. The testo 250 HACCP management system makes it possible, for the first time, to 100% digitally control all measurements, checks and documentation in the context of HACCP. The testo 250 truly provides a break-through solution to a number of issues experienced by the food industry.

HACCP (Hazard Analysis and Critical Control Points) is an official set of process food safety guidelines which covers all stages of the food production chain and is something that all companies involved with food production and distribution need to strictly adhere to. In 1959, the concept was developed by NASA and the Pillsbury Corporation to ensure impeccable quality for the first manned space flights. Its main objective is to avoid possible dangers in food production, in order to protect the health of consumers.

Documentation of all processes and quality data is crucial in HACCP. Traditionally, the concept could only be realised through huge quantities of checklists, forms and documents. This becomes a problem when clearly assigned proof needs to found quickly, for example in cases of audits or complaints.

As part of routine inspections, an enforcement officer will check that the business has an appropriate HACCP-based food safety management system in place. It is, therefore, of the utmost importance that food companies understand what is required of them, and that they also have the correct tools to monitor this.

Managing HACCP efficiently

Managing HACCP processes can be a lengthy procedure, involving a lot of time and work. Correct implementation requires countless checklists, papers and documents. If you need concrete proof from the HACCP process, for an audit or complaint, it can often be difficult to find quickly.

Historically it has been difficult to know for certain whether everyone involved is really carrying out their respective tasks according to the prescribed process. The complexity of such processes also often results in all those involved investing a great deal of time – time which could potentially be used for more profitable tasks. All in all HACCP management is a huge challenge throughout the food chain, but testo now has a solution to make this challenge much more manageable.

The testo 250 HACCP management system uses paper-free documentation of HACCP processes, and supports the guided set-up of a HACCP plan based on the Codex Alimentarius. It enables companies to trace all quality data on a single device and improve the efficiency of their HACCP processes. Recordings can then be used as proof of activity, so you can be certain that produce is being correctly monitored. This results in a considerable advantage. In short, having more efficient HACCP processes will save companies both time and money.

Using a completely digital system also minimises the possibility of human error which can occur when filling out checklists by hand. Responsible quality managers can then trace all quality data at the touch of a button, ensuring they are always prepared for unexpected inspections or audits.

A major advantage of the new HACCP management system is its ability to quickly be combined with an existing wireless LAN. As soon as an Internet connection is set up, all processes, proofs and measurement values will be collated and stored via the testo cloud. There they are securely stored and protected from data loss and manipulation.

Cockpit, Control Unit and Check

The testo 250 consists of the following components:

Cockpit: With the testo 250 HACCP Cockpit – the web-based control centre of the system – the quality manager defines the HACCP processes and correction measures, as well as all measurement and checking tasks. With the Cockpit it is possible for the user to analyse all measurement data, and view the status of set tasks. Features include simple checklist creation, task planning, extensive data analysis, easy access reports and the ability to create a HACCP plan.

Control Unit and probes: The compact testo 250 HACCP Control Unit was developed for the on-site staff entrusted with measurement and documentation tasks. It consists of a high-performance tablet with a durable protective cover, specially developed for use in rough, humid and hectic surroundings. To make optimum use of the Control Unit, the user can incorporate a temperature probe to take measurements. There are two compatible probes available – the testo 102-1 (standard wired plug in probe) and the testo 104IR Bluetooth (Infrared and penetration thermometer connected by Bluetooth).

App: The testo 250 HACCP Check App is pre-installed on the tablet and guides the user safely through each individual step of the HACCP process. Measurement values are either input directly or via Bluetooth. If measurement results are critical or limit values are exceeded, the App immediately picks up on this and provides instructions on corrective measures.

The intuitive App not only offers a paperless solution, but also practical and targeted functions for the following:

• Calendar overview of HACCP jobs to be done.

• Guided work through checklists. • Easy implementation and documentation of correction measures.

• Direct measurement data recording (requires an attachable probe).

• Tamper-proof data transfer by wireless LAN. • Documentation with photos. • Built in barcode scanning facility.

• Identification of users and locations by NFC technology.

• Printing of batch numbers, retention sample labels etc (requires a label printer).

Testo offers a wide range of equipment for food safety which will help you meet HACCP requirements and give the reassurance that food is being stored, manufactured, and processed safely.

Testo’s instruments include temperature monitoring systems, data loggers, thermometers, cooking oil testers, PH meters and much more. Whether it is for spot checks or long-term monitoring, from farm to fork, testo has the right instrument for the job. To arrange a no obligation demo of the testo 250 call testo on 01420 544433 or for more information please visit:

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