Food handlers

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