With numerous stringent U.S. regulations and guidelines around food safety compliance, it’s crucial for food industry professionals to utilize equipment that can rise to the challenge and meet HACCP and FSMA requirements. In this blog, we’ll explain why checkweigher inspection systems are an essential critical control point (CCP) to ensure food safety. To learn which checkweigher and metal detector models will work best for your business, contact a Yamato expert. 

What are the FSMA Requirements for Food Manufacturers?

The FDA estimates that 1 in 6 Americans get sick, 128,000 are hospitalized, and 3,000 die each year due to foodborne illnesses. In order to prevent the spread of foodborne illness as much as possible, the federal government enacted the Food Safety Modernization Act (FSMA) in 2011. This legislation is the most significant update to U.S. food safety laws in the 70 years prior to its enactment. The FSMA is a response to rapid changes in the global food system as well as an increased understanding of foodborne illnesses. 

The FSMA delineates clear steps on the supply chain that must be taken to keep food products safe. These steps implement preventative controls as part of a Hazard Analysis and Critical Control Point plan.

What is a HACCP?

According to the FDA, a Hazard Analysis and Critical Control Point (HACCP) is “a systematic approach to the identification, evaluation, and control of food safety hazards.” The goal of establishing HACCPs is to set parameters for food production managers to identify and correct hazards throughout the entire food production process. There are seven HACCP principles:

  • Conduct a hazard analysis.

Identify any biological, chemical, or physical hazards that may arise along your production line.

  • Determine the critical control points (CCPs). 

A CCP is a specific point in the food production process where a control measure must be implemented to prevent or eliminate a hazard. 

  • Establish critical limits. 

Set measurable minimum and maximum values to certify the effectiveness of a CCP, such as a target weight range and maximum detectable size of metal spheres. 

  • Establish monitoring procedures.

Implement procedures to regularly check that CCPs are adhering to their critical limits. 

  • Establish corrective actions.

Put plans in place to correct CCPs that are not operating within set parameters. This generally involves discarding hazardous product as well as analyzing and adjusting your process to prevent repeat errors.

  • Establish verification procedures.

Perform regular testing of  CCPs to ensure they are meeting performance expectations.

  • Establish record-keeping and documentation procedures.

Keep detailed records of your entire HACCP plan, including ongoing monitoring, corrective actions, and compliance verification.

We recommend using the FDA Food Safety Plan Builder to devise a plan that establishes HACCPs and meets all other regulatory requirements. 

How Do Integrated Checkweighers and Metal Detectors Confirm Product Safety as CCPs under the FSMA?

Checkweighers and metal detectors both serve essential functions to verify food safety and compliance. Checkweighers confirm the weight of the package matches the stated weight on the packaging. Metal detectors identify ferrous, non-ferrous, and stainless-steel objects – which become harmful to consumers at certain amounts – in food products. 

Checkweighers and metal detectors play a major role in the HACCP process:

  • Control physical hazards by detecting both weight deviations and metal content
  • Monitor product continuously to provide real-time data
  • Generate electronic records of all inspections, rejections, and performance tests
  • Reject any product with weight outside of the set calibrated limit
  • Enable regular testing and documentation to prove the equipment can detect the specified minimum particle size

Ensure Full HACCP and FSMA Compliance with Yamato Integrated Checkweigher Systems

Yamato checkweighers help protect the quality of your production line. These advanced checkweighing inspection systems guarantee unparalleled reliability and precision, verifying that your packaged products are of the highest standard. From checking package weight and content accuracy to detecting foreign objects with our inline metal detection, our checkweighers can manage every aspect of your packaging flow. 

Yamato isn’t a distributor or an agent. We are the weighing experts. The Yamato team is easily accessible and ready to offer you direct support. Our mission is to strengthen your operations with the best weighing equipment for your business. Contact us today to learn more about our checkweigher inspection systems with integrated metal detection.