| Undeclared allergens and allergen cross-contact | Wheat, milk, egg, soy, tree nuts, peanuts and sesame on shared mixers, ovens and packaging lines; airborne flour and powders; toppings and inclusions; rework; the wrong label or film | 2.8.1 Allergen Management, Mandatory (risk analysis 2.8.1.1, segregation 2.8.1.3, changeover cleaning that removes allergens "including aerosols as appropriate" 2.8.1.4, cleaning validation and verification 2.8.1.5, label accuracy 2.8.1.9, rework 2.8.1.10) | Allergen risk analysis, segregation, changeover procedures and validated cleaning, label approval and reconciliation records, allergen rework identification and traceability records |
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| Salmonella and other pathogens in low-moisture ingredients | Flour, nut butters, cocoa, dried egg and milk powders, seeds and spices, especially those added after baking or in products that aren't baked | 2.3.4 Approved Supplier Program; 2.4.3 Food Safety Plan; 2.4.4 Product Sampling, Inspection and Analysis | Supplier approval and certificates of analysis for higher-risk ingredients, hazard analysis that identifies which ingredients get a kill step |
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| Contamination after baking or cooking | Cooling, slicing, icing, filling, enrobing, seasoning and packaging of ready-to-eat product | 11.7.1 High-Risk Processes, where your hazard analysis treats post-bake product as high-risk food (areas after a "kill" step protected from raw materials and the staff who handle them); 2.4.8 Environmental Monitoring | Separation of raw and post-bake areas, a risk-based environmental sampling schedule (organisms, sites, frequency), results tracked and trended |
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| Survival of pathogens in under-baked product or growth in perishable fillings | Ovens and fryers used as a control step; cream, custard and meat fillings | 2.4.3 Food Safety Plan (validated critical limits); 2.5.1 Validation and Effectiveness; 11.6.2 Cold Storage, Freezing, and Chilling of Foods | Validation of bake or fry time and temperature where it's a control, monitoring records, filling temperature records |
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| Foreign material | Metal from mixers, sheeters, cutters and slicers; plastic, wood, glass; stones and other matter in flour and grain | 11.7.3 Control of Foreign Matter Contamination; 11.7.4 Detection of Foreign Objects (screens, sieves, filters and, where used, detectors) | Sifter and sieve checks, metal detector or x-ray checks and reject records, glass inventory, equipment inspections, no snap-off blades |
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| Stored-product insects and rodents | Flour silos, ingredient warehouses, sifters, dust in hard-to-clean areas | 11.2.4 Pest Prevention; 11.1.5 Dust, Insect, and Pest Proofing; 11.6.3 Storage of Dry Ingredients, Packaging, and Shelf Stable Packaged Goods | Pest prevention program and site map, trend records, stock rotation, storage cleaning frequency |
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| Chemical hazards | Mycotoxins such as aflatoxin in peanuts and corn, acrylamide in fried and baked products, cleaning chemicals, food-grade lubricants | 2.4.3 Food Safety Plan (hazard analysis); 2.3.4 Approved Supplier Program; 11.6.4 Storage of Hazardous Chemicals and Toxic Substances; 11.2.1.7 (food-grade lubricants); 2.8.1.1 (lubricants that contain allergens) | Hazard analysis covering chemical hazards, supplier specifications and certificates of analysis, chemical controls |
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| Compressed air and gases that touch product | Nitrogen-flushed snack bags, air knives, pneumatic conveying of flour and sugar | 11.5.5 Air and Other Gases (monitored at a risk-based frequency, at least annually) | Compressed air and gas testing records and filter maintenance |
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