Enhancing HACCP Decisions: A Comparative Risk Assessment for Table Olive Processing

Table olive processing comprises multiple stages in which physical, chemical, and biological hazards may occur. Although risk assessment is a core element of Hazard Analysis and Critical Control Points (HACCP) systems, the selection of assessment tools remains insufficiently standardized. This study compared a 4 × 4 risk matrix and Failure Mode and Effects Analysis (FMEA) for hazard evaluation in Spanish-style and Californian-style table olive processing. Hazards were assessed across 41 processing stages for Spanish-style olives and selected key stages for Californian-style olives using probability × severity in the 4 × 4 matrix and severity × occurrence × detection in FMEA. Significant hazards were further evaluated using the Codex Alimentarius decision tree to identify critical control points (CCPs) and strengthened prerequisite programs (PRPs). Both tools identified similar significant hazards, including biological hazards associated with fermentation, brine management, storage, container sealing, and heat treatment, as well as physical hazards from foreign bodies and chemical hazards related to heavy metals, pesticide residues, mycotoxins, and food-contact material migration. FMEA provided greater analytical detail through the detection parameter, whereas the 4 × 4 matrix was simpler and more practical for complex flow diagrams. Overall, both tools were suitable for HACCP-based risk assessment in table olive processing.