PRPs Training.ppt
- 1. Prerequisite Programs for Food Safety Management Systems Certification ISO 22000
- 2. Prerequisite Programs - PRPs PRPs are programs and practices put in place to ensure that the environment is clean, sanitary and appropriate for manufacturing safe product.
- 3. Prerequisite Programs For ISO 22000 the requirements for Prerequisite programs are found in: ISO 22000, section 7.2 ISO/TS 22002-1 provides more detail for Prerequisite programs that may be used to set up your programs ISO 22000
- 4. General Overview: Prerequisite Program Requirements Construction and layout of buildings Layout of premises and workspace Utilities - air, water, energy Management of purchased materials Waste disposal Equipment suitability, cleaning and maintenance Pest control Management of cross contamination Cleaning and sanitizing Recall and withdrawal Personnel hygiene and employee facilities Rework Food defense Warehousing Product information
- 5. Pre-requisite Programs Although there are differences in the specific requirements in each of the standards mentioned, the overall programs they all address key elements for maintaining the hygienic conditions of the manufacturing environment.
- 6. Sites General summary • You will need to ensure that your buildings are designed and constructed to protect food safety. The requirements address the condition of your facilities and the materials they are built with. The environment surrounding your facilities is also considered.
- 7. Sites • Sites shall be maintained in good order. • Vegetation shall be tendered, removed or otherwise managed to address animal food safety hazards. • Roads, yards and parking areas shall be well drained to prevent standing water and shall be maintained. • Where outside space is used for storage, stored items shall be adequately protected so as not to provided harbourage to pests and rodents. • Building must be soundly constructed, of durable materials which present no risk to product • Roofs shall be self-draining and shall not leak
- 8. Sites • Potential sources from the local environment shall be identified and assessed. Measures taken to protect against potential sources of contamination shall be documented and reviewed for effectiveness • Grounds around a feed plant shall be kept in a condition that will protect against contamination of feed and the harbourage of insects and pests. • Site boundaries shall be defined and documented • Access to the site shall be managed to address animal food safety hazards. Where it is not feasible to control access to the site, measures to prevent the introduction of hazards shall be taken.
- 9. Processes and Workspaces General summary • The layout of the building, the traffic patterns and internal construction, laboratories, and storage facilities must all minimize the risk of contamination of the production areas and product.
- 10. Processes and Workspaces • Internal layout shall be designed, constructed and maintained to facilitate good hygiene and manufacturing practices. • The movement patterns of materials, products and people and the layout of equipment shall be managed to protect against sources of contamination. • Process area walls, floors and floor-wall junctions shall be cleanable. Structural materials shall be resistant to cleaning systems applied. • External openings intended for transfer of materials shall be managed to prevent entry of foreign matter, moisture and pests.
- 11. Processes and Workspaces • Facilities used to store ingredients; packaging and products shall provide protection from dust, condensation, drains, waste and other sources of contamination. • All packaged materials shall be stored off the ground and with sufficient space between the material and the walls to allow for inspection and pest control activities to be carried out. • A separate, secure (locked or otherwise access controlled) storage area shall be provided for Chemical (e.g cleaning materials, pesticides) that are not intended for inclusion into products.
- 12. Utilities – Water, air, energy General summary • Utilities must be routed in a manner that minimizes contamination. Determine quality requirements for water, air or gas that has any product contact. Make sure that ventilation removes excess steam, dust or odors.
- 13. Utilities – Water, air, energy • Water used as a product ingredient, including steam (e.g. during pellet conditioning), or in contacts with material, product or product-contact surface shall meet specified animal food safety requirements relevant to the product. • Exterior air intake ports shall be examined periodically for physical integrity. • The lighting provided (natural or artificial) shall allow personnel to operate in a hygienic manner and to carry out assigned animal food safety responsibilities. • Light fixtures shall be protected or equipped in such a way that materials, product or equipment are not contaminated in the case of breakage.
- 14. Waste disposal General summary • A system must be in place to manage waste and make sure that it does not accumulate in production. Clearly identified waste containers, waste management programs, drain flow and locations will all be part of this program.
- 15. Waste disposal • Containers for waste shall be: (a) Clearly identified for their intended purpose (b) Located in a designated area and closed when not in immediate use (c) Designed to be effectively emptied • Waste shall be managed in a manner that prevents it from becoming a source of food to pests. • Drains shall be designed, constructed and located so that the risk of contamination of materials or products is avoided. • Drains shall have the capacity sufficient to remove expected flow loads.
- 16. Equipment suitability, cleaning and maintenance General summary • The food contact equipment used in your facility must be constructed, maintained and cleaned to protect food safety. This includes the material it is made of, the design, a preventive and corrective maintenance program and cleaning programs.
- 17. Equipment suitability, cleaning and maintenance • Animal food equipment shall be fit for purpose and designed and constructed to facilitate cleaning and maintenance. • Product contact equipment shall be smooth, accessible, and cleanable and constructed of materials compatible with the intended use. • Thermal process equipment shall provide for the monitoring and control of temperature. • A preventive maintenance program shall be in place and shall include all devices used to monitor and/or control food safety hazards. Examples of such devices include screens and filters, air filters, magnets and metal detectors.
- 18. Equipment suitability, cleaning and maintenance • Maintenance requests that affect product safety shall be given priority. • Temporary fixes shall not put product safety at risk. A request for replacement by a permanent repair shall be included in the maintenances schedule. • All scales and metering devices used in the manufacture of animal food shall be fit for purpose for the range of weight or volume to be measured and shall be tested for accuracy regularly according to the risk.
- 19. Management of Ingredients General summary • Your program must address how you approve suppliers and what incoming material requirements you need to put in place to ensure that raw ingredients and materials are safe.
- 20. Management of Ingredients • Purchasing of materials that affect animal food safety shall be managed so that the suppliers used have the capability to meet the specified requirements. • The conformance of incoming materials to specified purchase requirements shall be verified. • Materials that do not conform to relevant specifications shall be handled under a documented procedure designed to prevent unintended use. • There shall be a defined process for the selection, approval and monitoring of suppliers. • Ingredient suppliers shall be required to notify the animal feed manufacturer of relevant changes in product composition.
- 21. Prevention of contamination General summary • A program must be established to minimize or prevent biological, chemical and physical contamination. This will include segregation of activities, allergen management, glass and brittle material management and other controls needed in your facility.
- 22. Prevention of contamination • Measures shall be put in place to prevent, control or detect potential contaminants identified by the hazard assessment. Examples include adequate covers over equipment or containers for exposed materials or products, use of screens, magnets, sieves or filters, use of detection/rejection devices such as metal detectors. • Procedure to prevent contamination shall be documented • Where identified by the hazard assessment, a zoning plan shall be implemented e.g • a) Separation of ingredients (or raw material) from finished products • b) Access control with requirements to change into required work wear •
- 23. Cleaning and Sanitation General summary • Define and implement cleaning and sanitizing programs that include specifying what must be cleaned/sanitized, the responsibilities, instructions, schedule, post-clean and pre-startup inspections. Monitoring for effectiveness is also a key element of this program.
- 24. Cleaning and Sanitation • Cleaning programmes shall be established and documented to maintain hygienic conditions. Programmes shall be monitored for continuing suitability and effectiveness. • Cleaning programmes shall specify, as a minimum: (a) areas and items of equipment to be cleaned (b) responsibility for the task specified (C) cleaning methods and frequency (d) monitoring and verification (e.g post cleaning inspections) • Cleaning programmes shall be verified for their continuing suitability and effectiveness.
- 25. Pest Control General summary • A trained, authorized person at your facility or qualified contractor can be used to establish and manage your pest control program. The program must include eliminating access, minimizing infestations, detection, eradication and trending of results.
- 26. Pest Control • The organisation shall have a nominated person to manage pest control activities and/or deal with appointed expert contractors at the site. • Pest management programs shall be documented and shall identify target pests, address plans, methods, schedules, control procedures and where necessary, training requirements. • Animal food production and storage buildings shall be maintained in good repair. Holes, drains and other potential pest access points shall be sealed.
- 27. Pest Control • Storage and material handling practices shall be designed to minimize availability of food and water to pests. Spilled material shall be controlled to prevent availability to pests. • Material found to be infested shall be handled in such a way as to prevent contamination of other materials, product or the establishment. • Pest monitoring programmes shall include the placing of detectors or traps in key locations to identify pest activity. • Control and eradication measures shall be put in place immediately after evidence of infestation is reported.
- 28. Personal hygiene and facilities • General summary • Your facility will need to establish policies for work wear, protective clothing, personnel hygiene, facilities for employees, eating and drinking policies, illness and injury policies and personal behavior policies to protect the hygiene and sanitation of the production environment.
- 29. Personal hygiene and facilities • Requirements for personal hygiene and behaviours shall be established and documented. • All personnel, visitors and contractors shall be required to comply with the documented requirements. • Personnel hygiene facilities shall be available, clearly designated and maintained as necessary for animal food safety. • All human food shall be stored, prepared and consumed in designated areas. • Personnel, who work or enter into areas where exposed materials are handled, shall wear work clothing that is fit for purpose, clean and in good condition. (E.g. free from rips, tears and/or fraying material)
- 30. Personal hygiene and facilities • People known/suspected to be infected with or carrying an illness transmissible through animal food shall be prevented form handling animal food or material contact surfaces. • Employees working in food contact operations shall under go medical examinations every 6 months (including site catering) - ZABS requirement. • Personnel in production areas shall be required to wash: (a)Before starting any working shift (b) Immediately after using the toilet (c) Immediately after handling any potentially contaminated material or contaminants e.g. pesticides.
- 31. Rework General summary • Develop procedures to ensure that rework is handled, stored and used correctly to protect food safety. Address traceability, acceptable use including quantities, storage and labelling.
- 32. Rework • Rework shall be stored, handled and used in such a way that product safety, traceability and regulatory compliance are maintained. • Stored rework shall be protected from contamination and shall not provide a source of food to pests. • Segregation requirements for rework, e.g. medications, materials prohibited or toxic to certain species shall be established and documented. • Rework shall be clearly identified and/or labelled to allow traceability. Traceability records for reworks shall be maintained.
- 33. Product withdraw procedures General summary • Have a system in place so you are prepared to conduct a recall if it is necessary. This includes having a list of key contacts available.
- 34. Product withdraw procedures • System shall be in place such that products failing to meet required animal food safety standards can be identified, located and removed from all necessary points of the supply chain. • Where products are withdrawn due to immediate health hazards; the safety of other products produced under the same conditions shall be evaluated • The product withdrawal programme shall be tested through a “mock recall” a minimum of once a year and the records of such mock recalls shall be maintained.
- 35. Warehousing and Transportation General summary • Define how materials will be stored to protect food safety. Address warehouse conditions, organization and segregation, and vehicles.
- 36. Warehousing and Transportation • Materials and product shall be stored in clean, dry, well- ventilated spaces protected from dust, condensation, fumes or other sources of contamination. • Waste materials and chemicals (cleaning products, pesticides and lubricants) shall be stored separately. • A separate area or other means of segregating materials identified as non-conforming shall be provided. • Specific stock rotation systems (e.g FIFO) shall be observed. • Product returned from distribution shall be assessed for animal food safety hazards and handled accordingly. Defective products shall be stored in a separate and secure area.
- 37. Warehousing and Transportation • Vehicles, conveyances and containers shall be maintained in a state of repair, cleanliness and condition consistent with material and product specifications. • Vehicles, conveyances and containers shall provide protection against damage or contamination of the product. • A hazard assessment shall be conducted to determine when cleaning is required. Cleaning procedures shall be documented and cleaning actions between loads shall be recorded.
- 38. Product Information General summary • This program is to ensure that you present the correct information to consumers through labeling, websites, advertisements and other methods.
- 39. Product Information • Information on content and intended use of animal food products shall be communicated to customers (e.g on a product label). • Procedure shall be in place detailing the correct labelling of products in accordance with applicable regulations.
- 40. Food defence, biovigilance and bioterrorism General summary • Your facility, processes and procedures must protect your product from intentional acts such as sabotage, vandalism or terrorism. Consider the security of your facility and of the product during transport. Identify sensitive points in your processes and means of protecting them.
- 41. Food defence, biovigilance and bioterrorism • The organisation shall assess animal food safety hazards reasonably expected to occur by potential acts of sabotage, vandalism or terrorism and shall put in place protective measures. • Access control - Sensitive areas within the site shall be identified, mapped and subjected to access control
- 42. Formulation of product • General summary • This program ensures that compounded animal feed is formulated in a manner that is consistent with the intended use of the product and that formulation procedures manage the use of ingredients that contain nutrients which can be harmful to certain classes of animals.
- 43. Formulation of product • Compound animal food shall be formulated in a manner that is consistent with the intended use of the product. • Formulation procedures shall be in place to manage the use of ingredients that contain nutrients that can be deleterious to certain classes of animals.
- 44. Management of Medication • General summary • You need to have a program that ensures that products are protected from unintended medication cross contamination by strict control measures.
- 45. Management of Medication • Medications present in product shall be declared on the label of such products. • Products shall be protected from unintended medication cross-contact by the use of flushing or batch sequencing. • Procedure to prevent cross contact shall be documented. • Medications shall be stored in a dedicated area and access to medications shall be restricted to authorized personnel
- 46. Specification for services • For services that have an impact on food safety, the animal food manufacturing organization shall have specified requirements and manage the services in conformance with the requirements of clause 6 • Example of services include water utilities, scale calibration and transportation
- 47. Training and supervision of personnel • The organisation shall train and supervise personnel, including contractors and visitors, in the application of the animal food safety principles and practices commensurate with their activity. • Training of personnel with respect to animal food safety principles and practices shall be documented.
- 48. REFERENCES 1. PAS 222 : 2011 Pre-requisite programmes for food safety on the manufacture of food and feed for animals 2. www.22000-Tools.com