How to Determine Critical Control Points (CCPs) In a Tuna Sandwich Making Process

When making food, have you ever wondered which steps are the most important for keeping it safe? That’s where Critical Control Points (CCPs) come in! A Critical Control Point is a step in food preparation where a hazard (something that could make food unsafe) can be prevented, eliminated, or reduced to a safe level. These hazards could be:

1. Biological (bacteria, viruses, or mold)
2. Chemical (cleaning products, food allergens, or natural toxins)
3. Physical (glass, metal, or plastic pieces)

But how do we know which steps are Critical Control Points (CCPs) and not just regular control points? We use a CCP Decision Tree, a series of yes/no questions that help determine whether a step is critical to food safety.

For each step in the process, we ask the following:

1. Are there any significant food safety hazards (biological, chemical, or physical) at this step?
   • If NO → This step is not a CCP (though control measures may still be needed).
   • If YES → Move to question 2.
2. Is there a control measure in place to prevent, eliminate, or reduce the hazard to an acceptable level?
   • If NO → This step must be a CCP (since no control measure exists).
   • If YES → Move to question 3.
3. Can the hazard be eliminated or reduced to a safe level later in the process?
   • If YES → This step is not a CCP (because a later step will control the hazard).
   • If NO → Move to question 4.
4. Is this the last step where control can be applied to prevent, eliminate, or reduce the hazard to an acceptable level?
   • If NO → This step is not a CCP.
   • If YES → This step is a CCP.

Download a Printable Version of this CCP Decision Tree!

Let’s walk through how to identify Critical Control Points using a simple example: making a tuna sandwich with precooked tuna, cheese, mayonnaise, and powdered spices.

Identifying Potential Hazards

Before we determine CCPs, we need to spot possible hazards at each step of making the sandwich:

1. Receiving Ingredients – If the tuna, cheese, or mayonnaise has been stored at the wrong temperature before it gets to us, bacteria might grow.
2. Storage – After receiving, if the tuna, cheese, and mayonnaise are not kept cold (below 41°F or 5°C), bacteria like Listeria or Salmonella could multiply.
3. Preparation – If we don’t wash our hands or use clean utensils, we could spread bacteria onto the food.
4. Mixing Ingredients – If we leave the tuna and mayonnaise out at room temperature for too long, bacteria could grow quickly.
5. Assembling the Sandwich – If hands, cutting board and utensils are dirty, contamination can occur.

Using the CCP Decision Tree

A CCP Decision Tree helps us determine whether a step in food preparation is a Critical Control Point (CCP) or just a regular control point (CP). The decision tree consists of a series of yes/no questions designed to identify steps that are critical to preventing foodborne illness. Let’s apply it to our tuna sandwich preparation by following the decision tree.

Step 1: Receiving Ingredients

1. Are there food safety hazards at this step?
   Yes – Ingredients (tuna, cheese, mayonnaise) could arrive at unsafe temperatures, leading to bacterial growth.
2. Is there a control measure in place to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – The supplier is responsible for proper temperature control before delivery, but it must still be verified.
3. Can the hazard be eliminated or reduced to a safe level later in the process?
   No – If a contaminated shipment is missed during inspection and accepted, there is no step later in the process to fix it, as these are ready-to-eat ingredients.
4. Is this the last step where control can be applied to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – If we fail to reject unsafe ingredients at this stage, the hazard remains throughout the process.
5. CCP Status: CCP #1 – Receiving ingredients is a Critical Control Point (CCP) because it is the only opportunity to prevent unsafe food from entering the process. Strict monitoring of temperatures and quality at delivery is essential to ensuring food safety.

Step 2: Storage (Refrigeration of Tuna, Cheese, and Mayonnaise)

1. Are there food safety hazards at this step?
   Yes – If stored above 41°F (5°C), bacteria such as Listeria or Salmonella can grow.
2. Is there a control measure in place to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – Refrigeration keeps the ingredients at safe temperatures, slowing bacterial growth.
3. Can the hazard be eliminated or reduced to a safe level later in the process?
   No – Since this is a ready-to-eat food, bacterial growth cannot be reversed.
4. Is this the last step where control can be applied to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – If refrigeration fails, bacteria will multiply, and there will be no further step to kill or remove them.
5. CCP Status: CCP #2 – Proper refrigeration is critical because failing at this step makes the food unsafe.

Step 3: Preparation (Handwashing, Clean Utensils, Preventing Cross-Contamination)

1. Are there food safety hazards at this step?
   Yes – Contamination can occur from dirty hands, knives, or cutting boards.
2. Is there a control measure in place to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – Proper handwashing, utensil sanitation, and clean surfaces reduce contamination risk.
3. Can the hazard be eliminated or reduced to a safe level later in the process?
   No – If bacteria contaminate the food, there is no cooking step to kill them.
4. Is this the last step where control can be applied to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – If contamination occurs here and is not controlled, it remains in the final product.
5. CCP Status: CCP #3 – Proper hygiene and sanitation during preparation are critical to food safety.

Step 4: Mixing Ingredients (Time-Temperature Control)

1. Are there food safety hazards at this step?
   Yes – If tuna and mayonnaise are left out at room temperature for too long, bacteria can multiply rapidly.
2. Is there a control measure in place to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – Monitoring time and temperature can prevent unsafe bacterial growth.
3. Can the hazard be eliminated or reduced to a safe level later in the process?
   No – If bacteria grow to dangerous levels, there is no cooking step to eliminate them.
4. Is this the last step where control can be applied to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – If food sits too long at unsafe temperatures, bacterial growth cannot be reversed.
5. CCP Status: CCP #4 – Time control at this step is critical to prevent bacterial growth.

Step 5: Assembling the Sandwich

1. Are there food safety hazards at this step?
   Yes – Contamination can occur if hands, the cutting board, or utensils are dirty.
2. Is there a control measure in place to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – Using sanitized utensils and clean hands reduces the risk.
3. Can the hazard be eliminated or reduced to a safe level later in the process?
   No – If contamination is not noticed, the sandwich may be served and consumed with harmful bacteria.
4. Is this the last step where control can be applied to prevent, eliminate, or reduce the hazard to an acceptable level?
   Yes – If contamination occurs here, there is no further opportunity to correct it.
5. CCP Status: CCP #5 – Assembling the sandwich is a Critical Control Point (CCP) because contamination may go undetected and cannot be corrected later. To prevent contamination, strict hygiene and sanitation practices must be enforced before and during sandwich assembly.

Summary of CCPs Identified

Why Identifying CCPs Matters

Critical Control Points (CCPs) are the last opportunities to prevent foodborne illness before food is served. If a CCP is not properly managed, food can become unsafe and cannot be corrected later. By using the CCP Decision Tree, food handlers can focus on the most critical steps in food preparation, ensuring food remains safe to eat.