Cook, chill, detect — three critical control points documented to the degree, the minute and the millimetre.
Overview
Built for chilled and frozen ready meal production, this system is organised around three explicit critical control points rather than a general hygiene framework. CCP-1 is cooking: core temperature of at least 75°C held for at least 30 seconds. CCP-2 is blast chilling: core to 4°C or below within 90 minutes. CCP-3 is metal detection, at ferrous 1.5 mm, non-ferrous 2.0 mm and stainless steel 2.5 mm. Each step has its own monitoring record, and the Ready Meals HACCP Plan and Study holds the hazard analysis behind them.
Documentation then follows the meal past those steps, because a cook-chill product moves through several temperature states before anyone eats it: reheating, hot holding and cold holding all have records of their own. Category risks are procedurised by name — cross-contamination prevention and high-care control, and emergency preparedness and business continuity for chiller failure or utility loss — alongside an equipment, facility and high-care checklist and an annual internal verification. CCP monitors are authorised through a training module before they sign a log, and the stated limits need validating on your own equipment.
What this system covers
- Cooking at CCP-1 — core temperature, hold time, probe use and action on an undercooked batch
- Blast chilling at CCP-2 — the 90-minute window to 4°C, loading discipline and chiller performance
- Metal detection at CCP-3 — detector sensitivities, test-piece routines and reject handling
- Reheating, hot holding and cold holding after the critical steps
- High-care segregation and cross-contamination prevention — flow, changing discipline and equipment separation
- Allergen management on multi-recipe lines — matrix, risk assessment and changeover control
- Emergency preparedness and business continuity — chiller failure, utility loss and incident escalation
- Traceability and recall — batch records, mock recall and annual system verification
Who it's for
Chilled and frozen ready meal manufacturers, co-packers and central kitchens running cook-chill or cook-freeze lines. The buying moment is usually a retailer audit, or a scale-up at which informal temperature logs stop standing up to scrutiny. A technical manager populates the plan with their own products, validates the cook and chill limits, and puts a traceable system in front of the auditor.
By document type
Key documents
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From purchase to audit-ready
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Roll out the manuals, procedures, forms and checklists to build a working, certification-ready system.
Frequently asked questions
What exactly do I receive?
A downloadable ZIP containing the full set of ready-to-use documents for this toolkit — manuals, procedures, forms, records, checklists, guidance and training material, all in editable Word and Excel format. The exact document count is shown at the top of this page.
Are the documents really editable?
Yes. Every file is native Microsoft Word or Excel — no locked PDFs. Add your logo, change wording, and tailor the content to your organisation. The toolkit is yours to keep and reuse.
Does this certify my organisation?
No. These are documentation toolkits aligned to the relevant standard to help you prepare. Certification itself is issued by an accredited certification body after their audit. Our toolkits give you a strong, audit-ready starting point.
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Do I get updates?
Yes. If we revise this toolkit, you're entitled to the updated version at no extra cost — just contact us with your order details.
What is your refund policy?
Because these are digital products delivered instantly, all sales are final once downloaded. If you have any issue with your files, contact us and we'll make it right. See our Refund Policy for full details.
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