HACCP Plan — FUERST WIACEK
FUERST WIACEK
Version 1.1 | Food Safety — Hazard Analysis and Critical Control Points | Reviewed: 2026-05
1. Scope and Regulatory Basis
This plan covers the production of beer at FUERST WIACEK, Berlin. It applies to all products brewed, fermented, packaged, and dispatched on site: canned beer, steel kegs, and KeyKegs.
Regulatory basis:
| Regulation |
Scope |
| EU Regulation 852/2004 |
Food hygiene — mandates HACCP for food business operators |
| EU Regulation 1169/2011 |
Food information to consumers — allergen declaration |
| Lebensmittel- und Futtermittelgesetzbuch (LFGB) |
German food law |
| Verordnung (EG) Nr. 178/2002 |
General food law — traceability |
This plan was developed following the seven HACCP principles as defined by the Codex Alimentarius Commission (CAC/RCP 1-1969, Rev. 4-2003).
2. HACCP Team
| Name |
Role |
Responsibility |
| Lukasz Wiacek |
Brewmaster / Owner |
Plan owner, final authority |
| Production team |
Brewing, cellar, packaging |
Implementation and monitoring |
The HACCP plan is reviewed annually or following any significant process change.
3. Product Description
| Item |
Description |
| Product |
Craft beer — various styles (IPA, Pale Ale, Lager, Stout, Wheat Beer, etc.) |
| Ingredients |
Water, malted barley, malted wheat (some recipes), hops, yeast, adjuncts (dextrose, liquid sugars, Sinamar, oats, lactose, etc.) |
| Packaging formats |
Aluminium cans (330 ml / 440 ml), steel kegs (30 L / 50 L), KeyKegs (20 L / 30 L) |
| ABV |
Typically 3.5–8.5% |
| pH (finished beer) |
~3.9–4.5 |
| CO2 |
Carbonated — food-grade CO2 from approved supplier |
| Shelf life |
9 months (cans, hazy/IPA styles); 12 months (lagers, standard cans) — best before date printed on each unit |
| Storage conditions |
Cold (2–8 °C recommended); stable at ambient for transit |
| Allergens |
Gluten (barley) — present in all products. Gluten (wheat) — present in wheat beer styles. Gluten (oats) — present in oat-containing recipes. Milk (lactose) — present in lactose-containing recipes (e.g. milk stouts, pastry styles). All must be declared on the label of any product containing them per EU 1169/2011 Annex II. |
| Intended consumer |
General adult population; not suitable for persons with coeliac disease or gluten sensitivity. Standard alcohol warnings apply. |
| Intended use |
Ready to consume; direct retail, hospitality (on-trade), export |
4. Process Flow Diagram
Raw material receipt
(malt, hops, adjuncts, water, CO2, yeast, CIP chemicals)
│
▼
Dry goods storage (silo / warehouse)
│
▼
Milling (malt) ◄─── Magnet on intake
│
▼
Mashing (67 °C / ~60 min)
│
▼
Lautering
│
▼
Wort boil (≥ 100 °C / ≥ 60 min) ◄──── CCP 1
│
▼
Whirlpool + hop / adjunct additions
│
▼
Wort cooling (plate heat exchanger)
│
▼
Yeast pitching
│
▼
Fermentation
│
▼
Maturation / VDK check / dry hopping (where applicable)
│
▼
Carbonation
│
▼
Transfer to packaging
│
┌───┴───────────────┐
▼ ▼
Canning ◄── CCP 2 Kegging (steel keg / KeyKeg)
(seam integrity)
│ │
└───────┬───────────┘
▼
Labelling ◄──────────────────── CCP 3
(allergen declaration)
│
▼
Cold storage
│
▼
Dispatch
5. Prerequisite Programmes (PRPs)
PRPs are the foundation controls that create the hygienic conditions for safe food production. They are documented in the SOPs referenced below. Failure of a PRP is addressed through the relevant SOP — not through the CCP monitoring system.
| PRP |
Description |
Reference |
| Cleaning & Sanitation |
CIP of all process vessels, lines, and equipment before each use. Conductivity verification after rinse (< 0.15 mS). |
Brewhouse CIP, Wortway CIP, Tank CIP, Canning CIP, Yeast Brink CIP, Kegger CIP, Chemical Baths |
| Chemical Management |
Safe handling, storage, and disposal of CIP chemicals (caustic, acid, PAA). Correct concentration use. |
Chemical Management, CIP Up-Concentration |
| Water Quality |
Municipal mains water used for brewing and cleaning. Steam system water quality monitored weekly (pH, conductivity, hardness, sulfite). |
Steam Generator |
| Supplier Approval |
Raw materials (malt, hops, adjuncts, CO2, yeast) sourced from approved suppliers. Certificates of Analysis obtained and retained for malt (mycotoxins / pesticide residues). |
Procurement records |
| Foreign Body Control — Metal |
Magnet on malt intake / mill line captures metallic particles before grain enters the process. |
Mill operation |
| Foreign Body Control — Packaging |
Seamer professionally set up and calibrated annually; stable between services. No glass in the production area. Plastic parts from ingredient containers removed before addition (checked at manway). |
Annual seamer service record, Boil Additions |
| Allergen Management |
Allergen-containing raw materials (barley, wheat, oats, lactose/milk) identified per recipe and declared on the label. Correct label confirmed against packaging sheet before each run. No allergen-free claims made. |
Labeller Operation |
| Microbiological Monitoring |
Routine micro sampling of wort, beer, and environment. Results reviewed by brewmaster. |
Micro Sampling |
| Equipment Maintenance |
Planned and reactive maintenance of all process equipment. Pump motor diagnostics where required. |
Brewhouse Maintenance, Canning Maintenance, Pump Motor Diagnostics |
| Pest Control |
Mouse traps maintained in the malt room (the highest-risk area for rodent entry due to grain storage). Regular visual checks by staff throughout the site. Any pest sighting reported to brewmaster immediately and acted on. |
Staff observation; trap checks |
| Personal Hygiene |
Hand washing, appropriate PPE, no eating/drinking in production areas, illness reporting policy. |
Staff induction |
| Temperature Control |
Fermentation temperature monitored daily. Cold storage maintained. |
Fermentation Monitoring |
| Traceability |
Brew sheets record lot numbers for all raw materials. Batch records link raw materials → fermentation tank → packaging run. Recall capability within 4 hours. |
Brew sheets, production spreadsheet |
| CO2 Quality |
Food-grade CO2 from approved supplier with Certificate of Conformity. |
Supplier records |
6. Hazard Analysis
For each process step: hazards are identified, assessed for severity and likelihood, and a determination made whether the hazard is a CCP or controlled by a PRP.
Severity: H = High (serious illness/injury), M = Medium (moderate harm), L = Low
Likelihood: H = Likely without control, M = Possible, L = Unlikely
Significant: Yes if Severity H or (Severity M + Likelihood H)
6.1 Raw Material Receipt
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Mould / mycotoxins in malt (DON, OTA) |
H |
L |
Yes |
Approved supplier with CoA; visual condition check on receipt — delivery note stamped and signed by receiving operator |
No — PRP (supplier approval) |
| Biological |
Pathogenic bacteria on raw materials |
M |
L |
No |
Downstream kill step (boil — CCP1) |
No |
| Chemical |
Pesticide residues in malt / hops |
H |
L |
Yes |
Approved supplier with CoA; delivery note stamped and signed |
No — PRP (supplier approval) |
| Chemical |
Incorrect / unlabelled chemicals delivered |
H |
L |
Yes |
Chemical management SOP; verify labelling on receipt; delivery note stamped and signed |
No — PRP |
| Physical |
Foreign bodies in malt (stones, metal, wood) |
M |
M |
Yes |
Visual check on receipt; magnet on mill intake |
No — PRP (magnet) |
6.2 Malt Storage
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Mould growth (moisture ingress) |
H |
L |
Yes |
Dry storage; regular silo/warehouse inspection |
No — PRP |
| Biological |
Pest contamination |
M |
L |
No |
Pest control programme |
No — PRP |
6.3 Milling
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Physical |
Metal fragments from mill wear |
M |
M |
Yes |
Magnet on intake; equipment maintenance programme |
No — PRP (magnet captures metal before mash) |
6.4 Mashing (67 °C / ~60 min)
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Survival of vegetative pathogens |
H |
M |
Yes |
Not a kill step — controlled by downstream CCP1 (boil) |
No — controlled by CCP1 |
| Chemical |
CIP chemical residue in mash tun |
H |
L |
Yes |
Conductivity verification after CIP rinse (< 0.15 mS) |
No — PRP (CIP) |
6.5 Lautering
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Contamination from equipment |
H |
L |
Yes |
Controlled by downstream CCP1 (boil) |
No — controlled by CCP1 |
6.6 Wort Boil — CCP 1
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Survival of vegetative pathogenic microorganisms (Salmonella, E. coli O157, Listeria, etc.) |
H |
H (without control) |
Yes |
Full wort boil at ≥ 100 °C for ≥ 60 minutes destroys all vegetative pathogens |
YES — CCP 1 |
| Physical |
Foreign objects from hop / adjunct additions entering wort |
M |
M |
Yes |
Dosing vessel procedure; manway checks; visual |
No — PRP |
Note
The wort boil is the primary pathogen kill step for the entire brewing process. All upstream biological hazards (malt, mashing, lautering) are controlled here. No pathogen-safe product is possible without this step being completed correctly.
6.7 Whirlpool and Hop / Adjunct Additions
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Introduction of pathogens via hop additions (wort still >80 °C during WP) |
M |
L |
No |
Wort temperature during WP provides residual kill; downstream fermentation and acidity |
No — PRP |
| Physical |
Plastic parts / seals from containers falling into kettle |
M |
M |
Yes |
Pre-addition container inspection (caps, safety rings, seals removed before pouring) |
No — PRP |
6.8 Wort Cooling (Plate Heat Exchanger)
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Contamination from unwashed PHE / wortway |
H |
L |
Yes |
Wortway CIP after every use; wortway sanitation at boil start |
No — PRP (CIP) |
6.9 Yeast Pitching
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Contamination from poorly sanitised aeration line |
M |
L |
No |
PAA aeration line sanitation SOP |
No — PRP |
| Biological |
Contamination from yeast brink |
M |
L |
No |
Yeast brink CIP before every harvest |
No — PRP |
6.10 Fermentation and Maturation
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Spoilage by wild yeast or bacteria |
M |
L |
No |
Tank CIP; microbiological sampling; alcohol + low pH of beer are natural hurdles |
No — PRP |
| Biological |
Contamination during dry hopping |
M |
L |
No |
Manway sanitation; tank overpressure maintained where possible |
No — PRP |
| Chemical |
Yeast autolysis flavour contamination |
L |
L |
No |
VDK and fermentation monitoring |
No |
6.11 Carbonation
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Chemical |
CO2 impurities (non-food-grade CO2) |
H |
L |
Yes |
Food-grade CO2 from approved supplier with CoC |
No — PRP (supplier approval) |
6.12 Canning / Can Seaming — CCP 2
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Post-process contamination through defective double seam |
H |
M (without monitoring) |
Yes |
Double seam integrity within specification — seam height, seam thickness, body hook, cover hook |
YES — CCP 2 |
| Biological |
Contamination from inadequately sanitised filler |
H |
L |
Yes |
Canning line CIP + sanitisation before every filling run |
No — PRP (CIP) |
| Physical |
Metal or debris from canning line entering product |
M |
L |
No |
Equipment maintenance; line inspection before run |
No — PRP |
6.13 Kegging (Steel Keg / KeyKeg)
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Contamination from inadequately cleaned keg |
H |
L |
Yes |
Kegger CIP for steel kegs; KeyKegs are new/disposable |
No — PRP |
| Biological |
Contamination at coupling / fill connection |
M |
L |
No |
CO2 purge before fill; PAA bath for connections |
No — PRP |
6.14 Labelling — CCP 3
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Chemical / Allergen |
Incorrect or missing allergen declaration — barley (gluten, all products), wheat (gluten, some), oats (gluten, some), lactose/milk (some) |
H |
M (without control) |
Yes |
Pre-run label verification against packaging sheet; correct job selected on Videojet; physical label matched to product and recipe |
YES — CCP 3 |
| Chemical / Allergen |
Wrong label applied to wrong product |
H |
L |
Yes |
Label roll confirmed against SKU before loading; packaging sheet cross-check |
YES — CCP 3 |
Warning
Allergens present in FUERST WIACEK beers depending on recipe: gluten (barley) — all products; gluten (wheat) — wheat styles; gluten (oats) — oat-containing recipes; milk (lactose) — lactose-containing recipes. All must be declared on the label of every product containing them. Mislabelling is a serious allergen risk — this is treated as a CCP.
6.15 Cold Storage and Dispatch
| Hazard type |
Hazard |
Severity |
Likelihood |
Significant? |
Control measure |
CCP? |
| Biological |
Spoilage at ambient temperature (short transit periods) |
L |
L |
No |
Beer is shelf-stable at ambient for transit; best-before date controls shelf life |
No |
| Physical |
Packaging damage in transit |
L |
L |
No |
Appropriate packaging, palletisation |
No |
7. CCP Summary and Monitoring Plan
CCP 1 — Wort Boil
|
|
| Hazard controlled |
Biological — vegetative pathogenic microorganisms |
| Critical limit |
Wort temperature ≥ 100 °C for ≥ 60 minutes (full boil duration) |
| Monitoring method |
Temperature sensor monitored continuously by Botec automation system; visual confirmation of active boil |
| Monitoring frequency |
Continuous (automated) |
| Responsible person |
Brewer on shift |
| Corrective action |
If temperature drops below 100 °C: identify cause (steam supply, burner fault), restore temperature, extend boil to achieve minimum 60 min at ≥ 100 °C. If boil cannot be maintained: do not advance recipe; contact brewmaster. |
| Records |
Botec batch record (time/temperature log per brew); brew sheet |
| Verification |
Botec records reviewed by brewmaster; monthly review of brew records |
CCP 2 — Can Seaming (Double Seam Integrity)
|
|
| Hazard controlled |
Biological — post-process contamination through defective seam |
| Critical limit |
Double seam within machine specification for seam height, seam thickness, body hook, cover hook. No sharp or cut seams. No broken chuck walls. |
| Monitoring method |
Seamer professionally set up and calibrated annually — seam dimensions verified at setup. Visual inspection of first cans at start of each run. Any defective or unusual seam reported and investigated immediately. |
| Monitoring frequency |
Annual professional setup; visual check per run start; immediate response to any observed defect during production |
| Responsible person |
Packaging operator (per-run visual); external technician (annual setup) |
| Corrective action |
If a defective seam is observed: stop the line immediately. Contact brewmaster. Quarantine all cans from the affected run. Arrange seamer inspection before restarting. |
| Records |
Annual seamer service record (setup dimensions, technician sign-off) |
| Verification |
Annual service record reviewed by brewmaster; seamer rolls & seam check SOP followed at annual service |
CCP 3 — Allergen Labelling
|
|
| Hazard controlled |
Chemical/Allergen — incorrect or missing allergen declaration (gluten / wheat) |
| Critical limit |
Every unit leaving the site must carry a label that correctly declares all allergens present in that product: gluten (barley) for all products; gluten (wheat) for wheat-style products; gluten (oats) for oat-containing products; milk (lactose) for lactose-containing products. |
| Monitoring method |
Pre-run: label roll physically confirmed against brew sheet (product name and SKU). Videojet job confirmed for correct product and best-before date. First labelled can inspected visually before releasing cans to conveyor. |
| Monitoring frequency |
Before every packaging run; re-checked after every label roll change mid-run |
| Responsible person |
Packaging operator |
| Corrective action |
If wrong label detected: stop line immediately. Quarantine all units from current run. Investigate root cause (wrong roll loaded, wrong job selected). Relabel or destroy affected product before release. |
| Records |
Packaging sheet — packaging preparation column (includes labels; operator initials confirm correct materials were checked and prepared before the run) |
| Verification |
Brewmaster spot-checks labelled product against brew sheet; annual label artwork review against product recipe list |
8. Corrective Action Summary
| Situation |
Immediate action |
Investigation |
Records |
| CCP1 — boil temp drops below 100 °C |
Restore temperature; extend boil |
Identify cause (steam system, burner) |
Brew sheet note; Botec record |
| CCP1 — boil cannot be achieved |
Do not advance; hold batch; contact brewmaster |
Equipment fault investigation |
Batch hold record |
| CCP2 — defective or unusual seam observed |
Stop line immediately; contact brewmaster; quarantine all cans from the run |
Seamer inspection; arrange technician if required |
Brew sheet note; quarantine record |
| CCP3 — wrong label applied |
Stop line immediately; quarantine entire run |
Trace root cause (wrong roll loaded, wrong job selected) |
Brew sheet note; quarantine record |
| CCP3 — allergen missing or incorrect |
Stop line; quarantine; contact brewmaster |
Review all product from run; relabel or destroy |
Brew sheet note; corrective action record |
9. Verification Schedule
| Activity |
Frequency |
Responsible |
| Review Botec brew records (CCP1) |
Per brew |
Brewer / Brewmaster |
| Annual seamer service record reviewed (CCP2) |
Annual |
Brewmaster |
| Labelled product spot-check against brew sheet (CCP3) |
Per packaging run |
Brewmaster |
| Microbiological results review |
Weekly / per result |
Brewmaster |
| Full HACCP plan review |
Annual or after any process change |
Brewmaster |
| Supplier CoA review |
Per delivery |
Brewmaster |
| Internal hygiene audit |
Quarterly |
Brewmaster |
10. Record-Keeping
The following records are retained for a minimum of 2 years (or shelf life + 1 year where longer):
| Record |
Location |
Retention |
| Brewing sheets (raw material lots, temperatures, Botec batch; CIP wortway, steri wortway, CIP tank, CIP yeast brink — operator initials per step) |
Physical + production spreadsheet |
2 years |
| Packaging sheets (CIP cans, CIP kegger, packaging preparation including label confirmation — operator initials per step) |
Physical |
2 years |
| Delivery notes (stamped and signed — visual condition check on receipt of malt, hops, adjuncts, chemicals) |
Physical file |
2 years |
| Annual seamer service record (setup dimensions, technician sign-off) |
Physical file |
Permanent |
| Microbiological results |
Lab records |
2 years |
| Steam water quality (Steam Control Sheet) |
Google Sheets |
2 years |
| Supplier CoAs (malt, hops, CO2, chemicals) |
Physical / digital |
2 years |
| Corrective action records |
Physical file |
2 years |
| HACCP review records |
This document (version history) |
Permanent |
11. Plan Review History
| Version |
Date |
Changes |
Reviewed by |
| 1.0 |
2026-05 |
Initial plan |
Lukasz Wiacek |
| 1.1 |
2026-05 |
Corrections: name spelling; pest control updated to actual practice (visual checks + malt room traps); CCP2 monitoring revised to annual professional setup (no per-run seam sheets); CCP3 records tied to brew sheet operator initials; raw material record updated to stamped delivery note; CIP records updated to reflect initialled CIP log |
Lukasz Wiacek |