Drawing up a food safety plan for your supplement brand begins with documenting all the risks in your production chain and establishing control measures to eliminate or manage those risks. This plan is not only a legal requirement under European food legislation, but also a practical tool for ensuring the safety of your end product. In this article, we answer the most frequently asked questions about food safety plans for supplements, from mandatory components to when they should be reviewed.
What must be included in a food safety plan for supplements?
A food safety plan for food supplements must, as a minimum, include a hazard analysis, critical control points (CCPs), monitoring procedures, corrective actions, verification procedures and a record-keeping system. This is the core of an HACCP-based system, which is mandatory for all food producers operating within the European Union.
In practical terms, this means that your food safety plan must include the following elements:
- Product description and intended use: a full description of the supplement, including the target group and instructions for use
- Process flow chart: a step-by-step overview of the production process, from raw materials to the finished product
- Hazard analysis: identification of biological, chemical and physical hazards at each stage of the process
- Critical control points (CCPs): the stages where control is essential to prevent hazards
- Critical limits: measurable standards with which every CCP must comply
- Monitoring procedures: how and how often you check whether the limits are being met
- Corrective measures: what happens if a CCP falls outside the critical limits
- Records and documentation: evidence that the system is working and being followed
In addition to these core HACCP elements, there are specific considerations for supplements, such as allergen management, labelling accuracy and the traceability of raw materials. European Regulation (EC) No 852/2004 requires all food producers to implement an HACCP system. For supplements that make claims regarding health or sporting performance, additional requirements apply in terms of labelling and ingredient transparency.
What is the difference between HACCP, BRCGS and FSSC 22000?
HACCP is a legally required methodology for hazard analysis and risk management, whilst BRCGS and FSSC 22000 are voluntary, internationally recognised certification standards that go beyond the minimum legal requirements. HACCP forms the basis; BRCGS and FSSC 22000 build on this with additional requirements for quality management, audits and business processes.
HACCP: the legal basis
HACCP stands for Hazard Analysis and Critical Control Points. It is a systematic approach to identifying and controlling food safety risks. Every food producer in the EU is legally obliged to implement an HACCP system. It is not a certification, but a procedure that you must document and demonstrate that you are applying.
BRCGS: international certification standard
BRCGS (Brand Reputation through Compliance Global Standards) is an internationally recognised certification scheme that assesses compliance with HACCP, hygiene, traceability, allergen management, quality management and legal compliance. Major retailers and buyers often require this certification as a condition for doing business. BRCGS certification demonstrates that your production process is controlled and auditable.
FSSC 22000: ISO-based standard
FSSC 22000 is a certification standard based on ISO 22000 and supplemented by additional requirements. It focuses heavily on food safety management systems and is recognised by the Global Food Safety Initiative (GFSI). FSSC 22000 is widely used by manufacturers who also operate in international markets and require broad recognition.
For your supplement brand, the following applies: if you manufacture your own products, HACCP is the legal minimum requirement. If you wish to work with major retailers or international partners, BRCGS or FSSC 22000 certification will significantly enhance your credibility.
What risks do you need to analyse when it comes to powdered supplements?
For powdered supplements, you analyse three categories of hazards: biological hazards such as bacteria and moulds, chemical hazards such as heavy metals and pesticides, and physical hazards such as metal particles or foreign materials. The hazard analysis forms the basis of your food safety plan and determines which control measures are necessary.
Biological hazards are less prevalent in powders than in fresh produce, but they should not be overlooked. Moisture during production or storage can encourage mould growth. Chemical hazards, on the other hand, pose a greater risk in supplements: raw materials may be contaminated with heavy metals such as lead or cadmium, or with residues of pesticides and solvents. In addition, cross-contamination with allergens is a serious chemical risk, particularly when multiple products are manufactured on the same production line.
Physical hazards associated with powdered supplements include metal fragments from production machinery, as well as glass, wood or plastic. A metal detector or screening system is therefore a common control measure in powder production.
A thorough risk assessment also takes into account the vulnerability of the target group. Supplements are sometimes used by athletes who consume large quantities, which increases their exposure to any contaminants compared with that of the average consumer.
How do you identify critical control points for your production line?
Critical control points (CCPs) are identified by assessing, for each process step, whether a hazard is significant and whether control at that step is essential to eliminate the hazard or reduce it to an acceptable level. You do this using a decision tree, a structured tool from the HACCP methodology.
The decision tree asks a series of questions for each step in the process:
- Is there a control measure in place for the identified hazard?
- Does this step eliminate or reduce the risk to an acceptable level?
- Could the infection rate rise to an unacceptable level?
- Does a subsequent step eliminate the risk?
Based on the answers, you determine whether a step is a CCP or an operational control point (also known as an oPRP or OPRP). For powdered supplements, common CCPs include metal detection at the end of the production line and the sieving step to remove physical contaminants. Allergen control is often managed as an oPRP through cleaning validation and product sequencing.
Each CCP is assigned a critical limit: a measurable value that indicates when the process is under control. For metal detection, for example, this is the minimum detection sensitivity for ferrous, non-ferrous and stainless steel particles. Without defined critical limits, a CCP cannot be enforced or audited.
Who is responsible for the food safety plan within your brand?
Ultimate responsibility for the food safety plan always lies with the brand owner or director, but day-to-day implementation and management are delegated to a designated food safety team leader or quality manager. European legislation requires there to be a clearly identified person responsible for managing the HACCP system and keeping it up to date.
In practice, this means that, as a trade mark proprietor, you must appoint at least one person who:
- Has proven training in HACCP and food safety principles
- The food safety plan documents and manages
- Plans and carries out internal audits
- Records and follows up on corrective actions
- Suppliers are assessed against food safety criteria
If, as a brand, you do not have your own production facilities but outsource to a production partner, operational responsibility for the production process shifts to that partner. However, you remain responsible for the accuracy of the product specifications, the label information and compliance with legislation relating to your brand. It is advisable to set out in a contract which food safety responsibilities lie with you and which lie with the production partner.
When should you review or update your food safety plan?
Your food safety plan must be reviewed whenever there is a significant change to the product, process, raw materials or legislation, and at least once a year as part of a periodic review. An out-of-date plan that no longer reflects the actual situation is of no legal or practical value.
Specific reasons for a review include:
- Introduction of a new ingredient or raw material
- Changes to a formulation or production process
- New or amended legislation relating to food supplements or food safety
- An incident or deviation which demonstrates that the current plan is inadequate
- Changing suppliers for a critical raw material
- Expansion into a new product category
- Feedback from internal or external audits
The annual review does not need to result in a completely new plan, but it must be verifiable. Document what you have assessed, what you have changed and why. Certification audits such as BRCGS actively check whether the plan is up to date and whether changes have been incorporated in a timely manner. A well-maintained version history demonstrates that your food safety system is a living, breathing process and not merely a paper exercise.
How MixMasters can help with your food safety plan
If you have your range of supplements manufactured by a certified partner, you do not need to draw up the food safety plan entirely on your own. We actively support our customers in this area. We are BRCGS-certified and operate an HACCP-based quality system that is fully tailored to the production of powdered supplements.
What we offer in concrete terms:
- A proven food safety plan which has been drawn up in collaboration with specialist consultants and is tailored to your product range
- Support in ensuring that the product information on the label is correct, so that you comply with the legal requirements straight away
- Strict quality controls, traceability of raw materials and batches, and standardised procedures for production and cleaning
- Support from concept to production, including allergen management and documentation
- BRCGS certification as demonstrable proof of food safety for retailers and procurement partners
Whether you’re an established brand looking for a reliable manufacturing partner, or an ambitious entrepreneur keen to launch your own range of supplements, we’ll ensure your product is safe, compliant and ready for the market. Contact us and find out what we can do for your brand.
Frequently Asked Questions
As a small supplements brand, is a simplified food safety plan sufficient?
Ja, de Europese wetgeving biedt kleine bedrijven enige flexibiliteit in de vorm van ‘HACCP-gebaseerde procedures’, wat betekent dat je het systeem mag afstemmen op de schaal en complexiteit van jouw activiteiten. De zeven HACCP-principes blijven echter altijd van toepassing, ongeacht de bedrijfsgrootte. Wat wel mag vereenvoudigd worden, is de mate van documentatie en de formele structuur — maar de gevarenanalyse, CCP’s en monitoringprocedures zijn nooit optioneel.
How do I manage food safety if I outsource my entire production to a co-manufacturer?
When outsourcing, you, as the brand owner, remain ultimately responsible for the safety and legality of your product, even though the co-manufacturer carries out the production. Set out in the contract which food safety responsibilities lie with which party, and always ask for proof of certification such as BRCGS or FSSC 22000. In addition, regularly check that your partner’s product specifications and food safety plan still comply with your product requirements.
What common mistakes should I avoid when drawing up a food safety plan for supplements?
Een van de meest voorkomende fouten is het kopiëren van een generiek HACCP-plan zonder het aan te passen aan jouw specifieke product, grondstoffen en productieomgeving — dit maakt het plan juridisch en praktisch onbruikbaar. Andere veelgemaakte fouten zijn het niet bijhouden van registraties tijdens de productie, het ontbreken van vastgelegde kritische grenzen bij CCP’s, en het vergeten om het plan te herzien na een ingrediënten- of proceswijziging. Een voedselveiligheidsplan is een levend document, geen eenmalige administratieve taak.
How do I demonstrate that my food safety plan is actually being followed during production?
Naleving toon je aan door middel van consistente registraties: monitoringlogboeken bij CCP’s, reinigingsrapporten, leveranciersbeoordelingen, resultaten van interne audits en eventuele corrigerende maatregelenformulieren. Deze documenten vormen samen het bewijs dat jouw systeem niet alleen op papier bestaat, maar ook in de praktijk wordt uitgevoerd. Bij een inspectie door de NVWA of een certificeringsaudit zijn deze registraties het eerste wat wordt opgevraagd.
Do I need to draw up a separate food safety plan for each new supplement?
Niet per se — als het nieuwe supplement vergelijkbaar is qua productieproces, ingrediëntenrisico’s en doelgroep, kun je het bestaande plan uitbreiden met een productspecifieke risicoanalyse en productbeschrijving. Introduceer je echter een supplement met een nieuw type ingrediënt, een andere productievorm (zoals capsules versus poeder) of een andere doelgroep zoals kinderen of zwangere vrouwen, dan is een aparte of grondig herziene gevarenanalyse noodzakelijk. Het uitgangspunt is altijd: als de risico’s wezenlijk anders zijn, moet het plan dat weerspiegelen.
How long do I need to keep my food safety records?
European food legislation stipulates that records and documentation must be retained for at least two years, but for supplements with a longer use-by date, the rule of thumb is to retain documentation for at least as long as the product’s use-by date plus one year. Certification standards such as BRCGS apply similar guidelines and check during audits whether records are complete and accessible. Digital storage with version control is preferable to paper-based archiving due to its accessibility and traceability.
What is the difference between a CCP and an oPRP, and does that difference make a difference in practice?
Een CCP (Critical Control Point) is een processtap waarbij overschrijding van de kritische grens direct leidt tot een onveilig product en waarbij het product moet worden tegengehouden of vernietigd. Een oPRP (operationeel Prerequisites Programme) is een beheersmaatregel die bijdraagt aan voedselveiligheid, maar waarbij een afwijking niet automatisch betekent dat het product onveilig is — de beoordeling is contextueel. In de praktijk maakt dit verschil voor de intensiteit van monitoring, de documentatievereisten en de corrigerende maatregelen: CCP’s vereisen strikte, aantoonbare controle bij elke productierun, terwijl oPRP’s doorgaans via periodieke verificatie worden beheerd.
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