Enhancing Safety Through Implementation of HACCP Plan for Black Soldier Fly (Hermetia illucens) Larvae Meal as Animal Feed

1. Introduction

Insect production as a protein source for animal and human consumption has gained increasing attention over the past decade due to its potential to meet global food demand while reducing pressure on conventional agricultural systems [1]. Insect farming offers several advantages, including high feed conversion efficiency, minimal space and water requirements, and a substantially lower environmental footprint compared to traditional livestock production [2,3]. Among the most promising species is the black soldier fly (Hermetia illucens), whose larvae are rich in protein, lipids, and essential minerals, making them a sustainable and functional alternative for animal feed [4].

However, using insects for food and feed presents significant challenges regarding product safety and quality. Insects are typically reared on substrates composed of agro-industrial residues, organic by-products, and recycled materials, which can introduce microbiological and chemical contamination risks [5,6]. Common hazards include pathogenic microorganisms (e.g. Salmonella, Listeria monocytogenes), heavy metal accumulation (lead, cadmium, arsenic), mycotoxins, pesticides, and allergens from chitin and other natural compounds [2,7]. These risks may be exacerbated in artisanal or small-scale systems with less stringent substrate and process control [8].

In response, regulatory bodies have begun to establish frameworks to ensure safety in insect production. In 2015, the European Food Safety Authority (EFSA) published a technical report on the risks of using insects for food and feed, emphasizing the need for specific industry regulations [9]. The European Commission authorized the use of insect protein in aquaculture feed in 2017, followed by approval for poultry and pig feed [8]. According to the International Platform of Insects for Food and Feed (IPIFF), European insect producers have marketed over 5,000 tonnes of insect-derived products since 2017, and the market is expected to reach 3 million tonnes by 2030 [8]. In contrast, Latin America still lacks robust regulation in this area, underscoring the need for targeted scientific data and policy frameworks to support local control measures and facilitate insect use as feed and food ingredients [10].

To address these risks and ensure product safety, the Hazard Analysis and Critical Control Points (HACCP) system has been widely adopted in the food industry [11] and is increasingly recommended for insect production [10,12,13]. HACCP enables the identification and assessment of physical, chemical, and biological hazards along the production chain, defining critical control points (CCPs) and parameters to mitigate risks [7]. Structured into 12 steps and 7 principles, HACCP provides a preventive framework that includes operational practices, control measures, and evidence-based verification, as recommended by the Codex Alimentarius Commission [11].

Producers and processors are strongly encouraged to address these hazards through good agricultural practices (GAP), good manufacturing practices (GMP), and preventive approaches based on HACCP, thus promoting safety management across the supply chain, in line with IPIFF guidance [8]. This methodology is particularly relevant for facilities involved in processing, transforming, and marketing insects beyond primary production, for both human and animal nutrition [13].

This study aims to explore the application of the HACCP plan to black soldier fly (Hermetia illucens) larvae meal (BSFLM) production, drawing on the literature and on previous and ongoing research at the Centre for Terrestrial Arthropod Research (CINAT), Universidad Nacional de Colombia. Biological, chemical, and physical hazards were assessed along the production chain, and CCPs were identified to ensure product safety. The analysis includes preventive strategies, control parameters, and corrective actions aimed at improving production and minimizing risk. A similar approach was previously applied to Tenebrio molitor meal, where HACCP was used to identify critical hazards and recommend control strategies to processors [10]. That experience provided a useful framework to strengthen food safety practices for Hermetia illucens and to extend these methods to other insect-based products.

2. Materials and Methods

2.1. Study Context and Data Sources

This study was conducted at the Centre for Terrestrial Arthropod Research (CINAT), Universidad Nacional de Colombia. The insect meal to be used as animal feed was produced from Hermetia illucens larvae reared on a mixed organic waste diet. Some processing steps differed slightly from those described in the literature, reflecting specific conditions applied at CTAR. This work does not present the details of BSFLM production but only the information relevant to the application of HACCP. The hazard analysis incorporated microbiological and toxicological data obtained in the meal produced.

2.2. HACCP Team Formation

The team was established in accordance with Codex Alimentarius recommendations [11,13,14]. It was multidisciplinary, including professionals in animal production (specifically Hermetia illucens farming), veterinary medicine, food science and technology, and quality management systems. All members contributed to each stage of analysis and recommendations.

2.3. Review of HACCP Prerequisites

The CINAT laboratory currently meets more than 50% of the Good Manufacturing Practices for Animal Feed (GMPAF), which are considered prerequisite programs (PRPs). These PRPs were assessed based on the Colombian Resolution 061252 of 2020, which establishes national guidelines for GMPAF [15].

2.4. Product Identification, Intended Use, and Process Description

A technical specification sheet was developed for black soldier fly larvae meal (BSFLM), detailing expected quality control parameters. Laboratory analyses were performed to obtain information on the compositional, microbiological and toxicological characteristics of the BSFLM. Information on the intended use was compiled, considering the target sector (animal feed), potential forms of commercialization, recommended labelling instructions, and guidelines for preparation or pre-processing. Relevant regulatory frameworks were consulted [13]. Additionally, a process flow diagram for BSFLM production at CINAT was also constructed. Each stage of the production process was defined, and key control variables were identified.

2.5. Hazard Identification, Risk Analysis, and Preventive Measures

Hazard analysis was carried out for each stage of the production process, based on an extensive literature review and data from ongoing research at CINAT BioInsectonomy Project (unpublished data). Hazard evaluations (i.e. cause and likelihood of occurrence) were informed by the HACCP team’s expertise, while severity (i.e. potential consequence) was determined using literature reports for each hazard. A five-level risk matrix was used to estimate hazard relevance by multiplying the probability of occurrence by the assigned severity score, reflecting potential impacts on product safety or animal health. Control measures were defined through team discussions, aiming to minimise the occurrence of each hazard through the application of GAP, GMP, PRPs, and risk management strategies, following Codex Alimentarius recommendations [10,11,16].

2.6. Identification of Critical Control Points, Critical Limits, Monitoring System, and Corrective Actions

Critical control points (CCPs) were identified using the Codex Alimentarius decision tree approach [8,10,16]. For each CCP, critical limits were established alongside a monitoring system. Then, corrective actions were defined to address deviations from control, following international recommendations [11,13,16].

2.7. Validation of Control Measures and Verification of the HACCP System

The HACCP team developed a proposal outlining how processors can implement these activities when applying a HACCP plan. These recommendations were formulated in line with guidance from the Codex Alimentarius [17] and the Food Safety and Inspection Service [18].

2.8. Documentation and Record-Keeping

Finally, the HACCP team developed a list of the minimum documents and records that should be maintained to support decisions made under the HACCP plan in accordance with Codex Alimentarius and Food Safety and Inspection Service (FSIS) recommendations [18].

3. Results

3.1. Final Product Description

(Table 1) provides a comprehensive technical overview of BSFLM, incorporating data generated under the BioInsectonomy Project.

3.2. Flow Diagram to Produce BSFL Meal

Figure 1 illustrates the processing stages to produce BSFLM and the variables to be controlled at each step. The flow diagram was reviewed and validated by the HACCP team in accordance with the established processing steps at CINAT.

3.3. Hazard Analysis and Preventive Measures

The hazard analysis (Table 2) identified the highest risks in the early processing stages, particularly during larval reception and substrate handling. Microbial contaminants such as Aspergillus spp., Escherichia coli, and Bacillus cereus, along with chemical residues including pesticides, heavy metals, and allergenic proteins, were classified as moderate to high risk. In subsequent steps such as sieving, blending, and drying, the nature of the hazards shifted toward cross-contamination, pathogen survival, and physical risks introduced by processing equipment, notably metal fragments from worn blades or damaged trays. These risks were mitigated through the implementation of good manufacturing practices, strict sanitation protocols, equipment inspection before and after use, and time and temperature controls. Additional actions such as larval surface cleaning, improved ventilation in drying areas, and the use of natural antimicrobial compounds like organic acids contributed to enhanced microbial safety.

Later stages of the process, including grinding, packaging, and storage, presented lower but still relevant risks. Potential hazards such as bisphenol migration from packaging materials and microbial viability during storage under freezing conditions were managed by using food-grade, BPA-free containers, hermetic sealing, reduction of moisture content below 10 percent, and continuous environmental monitoring. Across all processing steps, the integration of prerequisite programs, comprehensive staff training, and systematic hygiene and environmental controls supported a robust and reliable food safety system.

3.4. Identification of CCPs

The CCPs results revealed that while many hazards were effectively managed through existing preventive measures and PRPs, a limited number required formal CCP designation (Table 3). In the early stages of the process, particularly during larval reception and substrate sourcing, met the criteria to be CCPs. These findings underscore the importance of stringent supplier selection, substrate quality assurance, and routine laboratory testing at the point of raw material intake.

Further along the process, drying stage was established as a CCP. Despite upstream measures to reduce microbial loads, the drying step represents the final and most critical barrier for microbial inactivation. To be effective, the process must consistently maintain validated time and temperature combinations (at least 60 °C for 21 hours) across all batches. This step is essential to control residual pathogens such as Salmonella spp., Escherichia coli, and Staphylococcus aureus, which may remain viable after rearing or blending.

Other hazards such as the presence of Aspergillus spp., aerobic mesophilic bacteria, metal splinters, or bisphenol residues were deemed sufficiently controlled through robust PRPs, equipment inspections, facility hygiene, and handling protocols.

3.5. Establishment of Critical Limits, Monitoring System, and Corrective Actions

Table 4 presents the proposed critical limits for each identified CCP, as well as the monitoring system and corrective actions tailored to the capacities of small- and medium-scale BSFLM producers, based on CINAT’s experience and HACCP team input.

3.6. Validation and Verification of HACCP System

Table 5 proposes potential validation strategies for small-scale insect processors to demonstrate that one or more control measures, when properly implemented, effectively control a specific hazard. Although validation was not conducted in the BioInsectonomy study, these recommendations aim to help artisanal or low-tech processors approach validated safety conditions and improve market access.

Table 6 outlines the proposed verification system for the HACCP plan. Verification should be conducted by individuals not responsible for daily monitoring to ensure that all HACCP procedures are being followed. Strategies, frequency, and methods may vary by facility, and in some cases, a validation strategy may also serve as a verification method [11].

3.8. Required Documentation for HACCP Implementation

Proposed documents must demonstrate proper implementation of the HACCP plan, enable process traceability, facilitates regulatory audits and allow timely consultation of CCPs and critical parameters. It should also support verification and validation activities. The recommended records include: (1) operational records generated during the HACCP system’s operation; (2) a summary of the hazard analysis, including justifications for hazard identification and control measures; (3) the complete HACCP plan covering the 12 implementation steps; (4) all documents related to the validation of the HACCP plan; and (5) records of internal audits, corrective actions taken, and continuous improvement processes applied to each step.

4. Discussion

4.1. Product Technical Specification

The proximate composition of BSFLM (Table 1) revealed a slightly lower protein content than previously reported [64], while the lipid content exceeded the values documented by other authors [4,65]. Microbiological analyses confirmed an acceptable profile for animal feed use, except for aerobic mesophiles, which reached 15,000 CFU/g, above the threshold suggested by IPIFF <10,000 CFU/g [12,66]. This may be due to specific handling or processing conditions in the laboratory and can be effectively managed by strengthening hygiene practices, staff training, and prerequisite programs. Similar microbial results have been reported by other authors [67] which indicates that it is possible to achieve acceptable microbiological results with the thermal process applied to BSFLM.

4.2. Interpretation of the Results of the Hazard Analysis

The main hazards were concentrated in the first two processing stages, larvae reception and sieving (Table 2), due to the use of agro-industrial residues as substrates, which often contain various contaminants and are difficult to trace. These initial stages have been identified as critical control points for biological risks, as larvae typically retain microbial loads from the substrate environment in which they develop [33,41,46,47]. Certain studies have reported the presence of pathogenic bacteria and fungi during these phases, highlighting the importance of substrate monitoring and early intervention [48,57]. However, other research has shown that the larvae’s natural bioconversion activity may contribute to reducing microbial contamination during rearing. Some studies observed a decrease in microbial load associated with larval digestion, although this is not sufficient for complete decontamination [28,33]. The effect is more consistent when pretreated or heat-processed substrates are used, improving microbial safety outcomes [58,68].

Preventive measures should include strengthening supplier control programs and ensuring infrastructure that protects the product from cross contamination while allowing hygienic handling from larval manipulation to final processing. On the other hand, allergens classified as chemical hazards from larvae or some from substrates can be controlled by treating the substrate, fasting the larvae and reporting their presence on the product label. During the BioInsectonomy project, the CINAT laboratory implemented more than 50% of the prerequisite programs and was undergoing structural improvements. This context led to a long list of potential hazards that could likely be avoided in better equipped facilities with developed GMP systems.

It is therefore recommended that insect producers implement robust supplier control programs and formulate diets using pretreated substrates, such as fermented or heat-treated materials, to ensure safety prior to larval consumption. Fermentation may help reduce microbial loads and improve digestibility [69]. In addition, the sieving stage, often performed outdoors and without controls in small scale systems, should ideally be conducted in enclosed, controlled environments to prevent contamination during handling and exposure.

In this study, a final sieving step was not applied after grinding, as the fine powder texture obtained using the high-speed blender made it unnecessary. The HACCP team determined that under these specific conditions, using a high-performance new device, the risk of metal fragments was minimal. Nonetheless, it is advisable to include this step in other settings to reduce physical hazards such as metal particles from grinders or residual substrate contaminants, as noted in previous studies [70].

In all cases, it is essential that insect meal producers apply HACCP methodology to assess whether a hazard is likely to occur depending on the specific conditions of their production system. As previously mentioned, the HACCP team identified the main CCPs (Table 3) under these conditions in the larval reception and production stages (mainly for chemical hazards such as heavy metals, mycotoxins, pesticides, and allergens), and in the drying stage (for the control of biological hazards). Applying adequate controls at these points ensures that BSFLM complies with safety standards for animal feed. Other hazards can be controlled or reduced to acceptable levels through the implementation of the preventive measures proposed at each step (Table 2).

The minimum and maximum limits for control variables (Table 4) were defined based on routine sample analysis for chemical hazards and temperature monitoring for biological hazards. Although this type of control may be difficult to implement for small-scale or subsistence producers due to cost limitations, robust GMPs remain essential to reduce risk and manage most hazards effectively. During the validation phase, HACCP guidelines recommend evaluating the adequacy of CCPs, critical limits, and monitoring procedures to ensure pathogen reduction [71]. This validation may rely on scientific evidence, expert judgment, pilot-scale trials, or lab simulations, followed by internal data collection [17,18]. In this study, the HACCP team proposed strategies such as the use of regulated, fungus-free, or pretreated substrates, supplier control, and staff training to reduce biological risks in the early stages of production. These measures require a proper sampling plan and experimental design, ideally a completely randomized setup, to confirm hazard control effectiveness with statistical confidence exceeding 95%.

4.3. Effectiveness of the HACCP System and Challenges in Implementation

The implementation of control measures at CCPs, such as time and temperature monitoring during drying, proved effective in reducing biological hazards, as confirmed by microbiological results. However, the process also revealed operational challenges and the need to strengthen other control measures that remained insufficient. For instance, substrate variability and environmental conditions affected the reliability of control during the reception stage, where hazard probability remained high.

Studies on BSFL production and derivatives have shown that consistency in substrate composition and controlled environmental conditions significantly improve product quality. Nutrient balance, particle size, and substrate texture also play a key role in larval nutrition and contribute to a differentiated nutritional profile in the final product [72].

The establishment of control measures and CCPs through HACCP offers a solid technical basis to support regulation and the safe trade of insect derived products [13]. Implementing HACCP in small and medium scale BSFL production can help define quality and safety standards that facilitate exports, open access to international markets, and improve producer competitiveness. These findings may also inform national regulatory frameworks and help simplify HACCP adoption and food safety oversight for insect-based products.

It is essential to implement training and monitoring programs to ensure HACCP effectiveness and compliance with international regulations [10]. A continuous review of the literature will help identify the best practices and tailor risk management strategies to local production systems. Further research should address emerging risks such as antimicrobial resistance and toxin accumulation and explore methods to improve the accuracy and specificity of HACCP systems. Enhancing hazard classification and control can support the production of high-quality insect meals that meet strict safety requirements [28].

5. Conclusions

The implementation of the HACCP system for BSFL meal production enabled a systematic hazard assessment, the definition of CCPs, and the establishment of monitoring systems and critical limits suitable for the CINAT context. However, it also revealed the challenges of applying this system rigorously in small scale settings, where limited resources may hinder adequate control at each stage. This experience showed that most local producers will need to redesign their prerequisite programs to achieve effective hazard prevention.