ISO 22000 with AI — HACCP, PRPs and traceability without rebuilding the dossier the night before the audit.

The problem

HACCP on the plan, the dossier on paper, reality on the floor — three worlds that don't talk to each other.

In most plants the food safety system doesn't fail by design — it fails in the distance between the documented HACCP and what actually happens each shift. The quality manager tells it like this:

1. The HACCP is complete — hazard analysis, CCPs identified, OPRPs defined. It passed the implementation audit. It lives in a document reviewed once a year.
2. The plant complies — most of the time — intermediate cleaning between allergen batches, cold room temperature, pest control, packaging integrity. But the evidence is generated on paper, on a SCADA screen, on a log sheet the operator signs and hands in at the end of the shift.
3. And then the gap — when the auditor asks you to cross the HACCP plan with the real evidence for batch 4729, it has to be rebuilt. And rebuilding means going sheet by sheet, island by island, calling past shifts. The classic system works 99% of the time. The 1% that ends up in RASFF (or in a major audit finding) is the batch whose evidence fell through the gap.

The sentence every food plant manager gets instantly: "my HACCP is fine — what fails is that between audits I don't know exactly what evidence I have for each CCP, each shift, each batch".

How it fits the IRIS system

iLEAN doesn't redo your HACCP — it seals the gap between the plan, the plant and the dossier.

The problem isn't a lack of HACCP — it's information living in islands that, at the critical moment (the pre-audit sprint, the recall for an undeclared allergen), cannot be put together in time. iLEAN acts as the filler that closes those gaps without asking you to change your HACCP plan, your ERP, your traceability system or the log sheets your people already use.

Edge sees what happens at the CCP. Connect captures the OPRPs at second zero. Writer builds the dossier while the plant produces. The person signs — never the other way round.

The iLEAN pieces applied to ISO 22000:

• iLEAN Edge — terminals with computer vision (CNN) over the CCPs: foreign body detection before packaging, allergen labeling verification, heat-seal integrity, cold room temperature. It detects and, where appropriate, holds the batch in milliseconds. It works without a network: if the plant loses WiFi, Edge keeps reading and holding batches, because food safety cannot depend on connectivity.
• iLEAN Tracer (Connect + integrations) — captures the OPRPs at second zero: intermediate cleaning between allergen batches (photo + checklist + signature), the temperature log of the old machine, the supplier certificate arriving by email, the incident an operator dictates through an earpiece. All linked to the batch and the workstation. It connects to the traceability system you already have (proprietary, SAP, or a multi-storey spreadsheet).
• iLEAN Writer + HACCP Agent — Writer turns the captured evidence into an auditable dossier with the structure ISO 22000 asks for (CCP records, OPRP records, validation of control measures, management review). The agent cross-checks the evidence against the HACCP plan and warns when a planned control has not been performed within its time window, or when an OPRP has gone days without a record. The person decides and signs.

See the full IRIS architecture →

Before and after

HACCP in sprints vs. an FSMS with live evidence

Aspect	HACCP + pre-audit sprint	With iLEAN Edge + Tracer + Writer
State of the dossier between audits	Partial, spread across shifts and islands	Live, complete, ready today
OPRP evidence (cleaning, temperature)	Paper log sheet, signed at end of shift	Captured at second zero, linked to the batch
Allergen labeling control	Checklist + a pair of eyes at SKU changeover	Edge verifies the printed label, holds if it doesn't match
Traceability of a batch	Days — searching across islands, calling shifts	Minutes — complete dossier, automatic
Operation without a network	n/a — depends on the online system	Edge keeps running as long as the panel has power
Multi-plant	Each plant with its own version of the spreadsheet	Rings per plant + consolidated corporate dossier

Impact estimate

Impact estimate for your plant — to be validated with your numbers.

The block below is an estimate to be validated with your plant's data. We put it forward so the committee has an order of magnitude; we refine it during the diagnostic.

• Mid-sized food plant with ISO 22000 (or FSSC 22000) + BRCGS, 2-4 lines, US/UK retail certification adding specific allergen rules.
• First value expected within a few weeks: Edge pilot on a packaging line with labeling verification + OPRP capture (intermediate cleaning) on one critical line.
• Indicative payback between 4 and 9 months, depending on the monthly volume of CCP/OPRP log sheets and the average cost of a recall or rework triggered by a non-conformity detected at the customer.
• Expected reduction in administrative evidence and dossier tasks: ≥30% (estimate to be validated). The hard lever is a single recall avoided — product pulled from the shelf, reverse logistics, destruction, brand damage. One recall pays for the pilot.

And the plant manager's fair objection

"What if the AI lets a mislabeled batch or an unfulfilled OPRP through?" — hallucination is a problem of free generation, not of anchored tasks. In tasks where the AI merely recontextualizes a data point (reading a label and comparing it against the batch recipe, reading a log sheet and linking it to the OPRP), the best models brought the error below 1.5% ^[1]. And even so, nothing critical is decided alone: iLEAN holds the batch or alerts about the missing evidence, and the person signs. The three security rings exist precisely for this.

^[1] OpenAI paper "Why Language Models Hallucinate", 2025 — on the reliability of AI in anchored tasks.