5 Prerequisite Programmes-PRPs

PREREQUISITE PROGRAMMES (PRPs) To HACCP
• Basic Conditions to ensure food safety

• Umbrella term covering various practices –
GAP Good Agricultural Practices
GMP Good Manufacturing Practices
GHP Good Hygiene Practices
GSP Good Storage Practices
GDP Good Distribution Practices
GTP Good Transportation Practices
GCP Good Consumer Practices
Etc
IICT/HABC_L3/Dec 2021/PRPs 1
Why prerequisite programmes?
• Most hazards are introduced due to poor hygienic practices
• Many hazards can be controlled by good hygiene practices
• The purpose of HACCP is to allow businesses to focus
control at critical points
• Without well functioning prerequisite programmes we risk
either :
– Identifying so many critical points that we cannot focus our
efforts and resources
– Not taking sufficient account of hazards that should have
been controlled by our GHPs
PRPs – the Foundation of HACCP
Focus on:
raw materials, product
and processes
HACCP
Focus on:
Production environment,
facility, programs and people
PRPs
Pre-Requisite Programmes
(Umbrella term which covers GAP, GMP, GHP and
other Good Practices)
• Covered in Codex General Principles of Food Hygiene
(CAC/RCP-1) and other Codex Hygiene Codes for various food
sectors (Milk : RCP 57, Tree nuts : RCP 6, etc)
• Covered in EC Regulations 852/2004
• Covered in USFDA (cGMP in CFR 21 Part 117)
• Covered in Food Safety and Standards Regulations (India)
Schedule IV of FSS (Registration & Licensing) Regulations,
2011
• And other similar documents
Sanitation
Current Good
Standard
Manufacturing
Operating
Practices
HACCP
Procedures
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE SANITATION
WAREHOUSING TRACEABILITY
SUPPLIER
AND AND PEST CONTROL
CONTROL
DISTRIBUTION RECALL
HACCP
cGMP SSOP
FACILITIES
Facilities
Broadly covers :
(Dealt in detail in later slides)
 Building
 Sanitary facilities
 Lighting
 Floors, walls, ceilings, doors
 Ventilation
 Water supply
 Waste disposal system
Facilities
Things to consider:
- design
- materials
- construction
Includes programs for the
- layout following:
 cleaning and sanitation
 maintenance and repair
 pest control
Facilities - Buildings
Must be designed & constructed to ensure:
 hygienic food handling
 effective cleaning & sanitation
 prevention of entry of pests
 safety of personnel
• Location, construction, With the following areas:

maintenance according to - rest & dining areas
sanitary design principles - locker rooms
• cleaned on a regular basis - landscape garden/trees
• Lay-out follows a straight- - comfort rooms
line process flow - medical clinic
Facilities - Buildings
Areas of a Plant:
• Receiving area
• Ingredient storage area
• Processing area
• Finished product
warehousing area
• Toilet area
Plant Lay-out
Facilities - An example of Factory Layout
Main entrance
A simple
factory layout Laboratory Administration
with all
departments
housed within a
single
compound
Production Area EA
Raw
Raw Material Storage FPS
materials
EA = Employee amenities
Final
FPS = Finished Products Storage products
Facilities - An example of Factory Layout
Raw
materials
Alternative
arrangements
of Raw Material Storage
departments
under a single Main
compound entrance
A
Production Area
A = Administration
L = Laboratory L
Finished Product Storage
EA = Employee EA
amenities
Final
products
Facilities - Sanitary Facilities
• Supplied with running water

• Handwashing sink near
processing area & comfort
rooms
• Taps of non-hand operable type
• Sinks provided with soap, nail
brush & clean towels
• Facilities for washing &
disinfecting equipment
Facilities - Lighting
• Source: fluorescent light with no glare &

shadow
• Provided with a cover (not of glass)
• Adequate and appropriate to location
• Required in food preparation area,
warehousing area, handwashing stations,
restrooms
Facilities - Floors
• Concrete, kept clean regularly, free of

debris, & properly drained (slope)
• Durable & water resistant
• No cracks, depression, or low areas
• Drains & gutters carefully planned &
located
Facilities - Walls & Ceilings
• Impervious to moisture, easily
cleanable, smooth & light colored
• Walls can be tiles, cement blocks, bricks,
concretes & metals
• Roof is simple, watertight, sufficiently
high, & adequately vented
• Coving between walls, walls & floors &
walls & ceilings should be sealed
Facilities - Doors
• Wide
• Open outward
• Made of corrosion-resistant or
suitable metal with adequate impact
strength
• Self-closing
• With air screen/air curtain or plastic
curtain/strip curtain
Facilities - Buildings Ventilation
• Remove obnoxious odors, heat, &

moisture from the plant
• Introduce fresh air, free of any
foreign odors & product
contaminants
• Provide a comfortable environment
for the employees
• Exhaust fan made of rustproof -
coated steel
Facilities - Water Supply
• Sufficient for operations from

adequate source
• Safe & sanitary quality (meeting
national standards)
• Suitable temperature
• Under pressure as needed
• Supplied by a reputable source
Facilities - Waste Disposal System
• Must meet regulatory requirements

• Must not cause pollution problems or
create breeding places for pests
• Sewage system is connected to the
public sewerage system or ETP
• Drains adequate to volume of waste
water generated
HACCP
cGMP SSOP
FACILITIES PREMISES
Premises
• area where the plant is located
and its surroundings
Includes programs for the

following: • maintained such that food is
kept from adulteration and
 cleaning and sanitation
contamination
 maintenance and repair
• should also consider security
 pest control
and safety
• location & size must support &
facilitate maintenance &
sanitary operations
Premises
Other considerations…
- no domestic animals - free from objectionable
- free from garbage/ waste odors, smokes, dust &
other contaminants
- free from pollution and dirt
- no flooding - no weeds or grass
- concrete roads & parking
space
HACCP
cGMP SSOP
PRODUCTION
FACILITIES PREMISES
EQUIPMENT
Production Equipment
• The primary objective is to prevent

adulteration and contamination of
raw materials and food products with
lubricants, fuel, fragments or any
other foreign matter from equipment
 constructed & installed in compliance with sanitary
principles
 Made of stainless steel/plastic and food-grade
 Made of impervious corrosion-resistant, easily
cleanable, resistant to chipping, & durable material
 Smooth seams on food-contact surfaces
 installed & kept in manner that supports

 preventive maintenance;
 replacement of malfunctioning parts;
 calibration; and
 cleaning schedules
Example of Bad Tank Design Example of Good Tank Design
Products cannot be fully drained Products can be fully drained
HACCP
cGMP SSOP
INGREDIENTS
PRODUCTION
FACILITIES PREMISES AND
EQUIPMENT RAW MATERIALS
Ingredients & Raw Materials
 Should be received, stored, handled & transported

under specific sanitary & environmental conditions
 Have Certificate of Analysis (COA) or Letter of
Guarantee (LOG) from suppliers
May be based on international standards &
publications based on scientific research
Should include sampling procedures, analytical
methodology & limits for acceptance
 Inspected as soon as it is issued from the stockroom
 Do sensory & chemical analysis
 Temperature of receipt in some cases (Fish,Meat,Milk,etc)
 Canned raw material should be analyzed according to quantity,
expiry date, and presence of dents, bulges, punctures, and leakage
 Fresh raw material should be analyzed based on weight, presence
of soil particles, bruises, discoloration
 Results of inspection should be recorded in a Raw Material
Inspection Form
 Return non-conforming raw materials to supplier
 Store properly;
separately
 Follow FIFO/FEFO
 When in doubt, throw it
out!
 Never put raw food
over prepared food.
HACCP
cGMP SSOP
INGREDIENTS
MATERIALS
PERSONAL HYGIENE
Personal Hygiene
 proof of good health (medical and dental certificates)

 health questionnaire & reporting agreement
 regular training of personnel
 procedures on handling personnel with illness
 Exclusion policy
 first aid kit accessible
Personal Hygiene - General Guidelines
A. Protective Clothing
 Suitable, company issued protective clothing shall be worn in food
production or storage areas
B. Laundry
 Protective clothing should be laundered regularly & effectively
 Adequate changes of protective should be available
 Storage facility for clean protective clothing
 Clean & soiled protective clothing should
have separate storage bins
C. Staff Change Facilities

 Personal lockers should be available
 Clean or soiled protective clothing should not be stored in lockers
 Periodic checking for compliance of locker should be done
D. Protective Hair Covering
 Disposable (if possible)
 Worn by all in production or storage areas
 Beards should also be covered
E. Personal Hygiene
 Wash hands prior to entering food production or storage areas and
in between food handling and after use of toilet
 Fingernails should be kept short, clean & unvarnished
 Gloves should be suitable, disposable, changed frequently & their
disposal controlled to avoid product contamination
 Cuts & grazes should be covered with waterproof plasters
 Avoid unhygienic practices – smoking, spitting, scratching face with
hand
F. Jewelry
 Observe company rules on jewelry while in food production areas
G. Eating, Smoking & Drinking

 Strictly restricted to designated areas
 Must be followed by proper hand-washing
H. Health Screening
 All staff who will be entering food production, storage & packing
areas should complete a Company Health Questionnaire
HACCP
cGMP SSOP
INGREDIENTS
RAW MATERIALS
CHEMICAL PERSONAL
CONTROL HYGIENE
Chemical Control
• Follow appropriate
segregation, labeling, use
& storage procedures of
food & non-food
chemicals
• Store under secure

conditions
HACCP
cGMP SSOP
INGREDIENTS
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE SANITATION
Cleaning and Sanitation
 Cleaning is removing the dirt you can see on a surface. Sanitizing is
reducing the unseen germs on a surface to a safe level.
 Clean and Sanitize all things that come in contact with food,
including equipments, surfaces and also which can be a source of
hazards – premises, buildings, utilities, etc
 Effective management of sanitation programs includes
education, participation & proper delegation of
responsibilities among employees
 Written detailed plans, procedures, schedules &
checklists regarding cleaning & sanitizing of food &
non-food processing equipment & facilities; Records
 Evaluation of existing cleaning procedures
 Detailed program of control for storage & use of cleaning & sanitizing
chemicals
HACCP
cGMP SSOP
INGREDIENTS
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
WAREHOUSING
AND
DISTRIBUTION
Warehousing and Distribution
Lot Identification
• Lot – a definitive quantity of a commodity produced under
essentially the same conditions
• Each container should be embossed or permanently marked in
code or in clear to identify producing factory and lot
• Permanent, legible and dated records and pertinent processing
details should be kept for a period exceeding the shelf-life of
the product but not exceeding two years
• Records regarding initial distribution of the lot should be kept
Storage Principles
• First-in-First-Out (FIFO) System should be implemented
• Create a system, such as dating goods on receipt and placing new
deliveries behind those already in storage to guarantee that FIFO
is followed
• Keep potentially hazardous foods out of the temperature danger
zone (40˚F - 140˚F or 4.4˚C - 60˚C).
• Store food products and raw materials separately only in
designated areas for storage in order to eliminate
the risk of contamination
• Keep all goods in clean, undamaged wrappers or packages
• Elimination/ minimizing contamination of goods during
storage
• Periodic inspection of product during storage
• Keep storage areas clean and dry
• this rule applies to dry storage, refrigerators, freezers,
and heated cabinets
• Keep vehicles for transporting food clean
HACCP
cGMP SSOP
INGREDIENTS
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
AND AND
DISTRIBUTION RECALL
Traceability and Recall
• System which implements proper coding or labeling of raw
materials and finished products in the anticipation of
circumstances which will require complete traces of product
retrievals
• All raw materials and products should be lot-coded and recall
system in place so that rapid and complete traces and recalls can
be done
Traceability and Recall
RECALL
• It is a firm’s voluntary removal of product from trade or
consumer channels (e.g. importers or manufacturers) to
protect the public from consuming adulterated or
misbranded products
• any corrective action by a company needed to protect
consumers from potentially adverse effects of a
contaminated, adulterated, or misbranded product
• Does not include a market withdrawal or stock recovery
HACCP
cGMP SSOP
INGREDIENTS
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
SUPPLIER
AND AND
CONTROL
DISTRIBUTION RECALL
Supplier Control
Types of Supplier Control used by firms:
1. Receipt of raw materials only from known sources of supply
2. HACCP Plan required for classification as ‘certified suppliers’
3. Inspection of ingredients and shipping containers for evidence of
unsanitary conditions
4. In-house lab analysis and random sampling
5. Quick tests of indicator parameters used to assess acceptability
of raw materials
6. Screening of new vendors -initial sample analysis by outside
laboratory and random sampling for 6 months
7. Vendor audits performed by third parties.
8. Documentation of problems with supplier’s products
HACCP
cGMP SSOP
INGREDIENTS
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
SUPPLIER
AND AND PEST CONTROL
CONTROL
DISTRIBUTION RECALL
IICT/HABC_L3/Dec 2021/PRPs •cont

50
Pest Control
 Three steps for pest control
 Restrict entry
 Physical control
 Chemical control
 Effective measures that prevent the entry & proliferation
of pests from receiving, processing, packaging & storage
areas
 Establishments & surrounding areas regularly examined
for infestation
 Continuous application through effective sanitation & use
of chemicals
Pest Control
 Examples of Pest Control Program
 Double-screened windows & doors
 Self-closing door
 Elimination of cracks in floors & walls
 Double-screened gutter drains
 Placing garbage cans outside the plant & far
from the processing area
 Covered food storage
 Cleaning spills immediately
 Food storage 6 inches above the floor & from the wall
 Use of hanging flypapers & glue traps
 With the aid of a pest control company
MANAGING PREREQUISITE PROGRAMS
 Documentation
 Written guidelines & procedures
 Records of previously encountered problems
& solutions that were implemented
 Training
 Periodic
 Well-designed
 Will cater to all level of employees
 Verification Activities
 Routines performed by supervisors that guarantee the
implementation of prerequisite programs, corrective
actions & that programs are functioning as intended
PREREQUISITE PROGRAM ASSESSMENT
 Check existence & effectiveness during design

& implementation of HACCP plan
 Document & regularly audit progress
 Aspect that may be incorporated into HACCP
plan
Summary
• Prerequisite programmes are the basic conditions for the production of
safe food. In fact, it is the foundation on which HACCP System is developed
or established.
• Prerequisite programmes should include:
 Hygienic design of food handling, storage facilities and equipment
 Operational control standards for handling all ingredients and
materials
 Maintenance, cleaning & disinfection schedule
 Pest control
 Waste management
 Personal hygiene standards, equipment/clothing for personnel
 Hygienic transport standards, as appropriate
 Product information and labelling
 Training programmes
• Ensure that prerequisite programmes “will work effectively” through
validation

5 Prerequisite Programmes-PRPs

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PREREQUISITE PROGRAMMES (PRPs) To HACCP

• Basic Conditions to ensure food safety

• Location, construction, With the following areas:

• Supplied with running water

• Source: fluorescent light with no glare &

• Concrete, kept clean regularly, free of

• Remove obnoxious odors, heat, &

• Sufficient for operations from

• Must meet regulatory requirements

Includes programs for the

• The primary objective is to prevent

 installed & kept in manner that supports

 Should be received, stored, handled & transported

 proof of good health (medical and dental certificates)

C. Staff Change Facilities

G. Eating, Smoking & Drinking

• Store under secure

IICT/HABC_L3/Dec 2021/PRPs •cont

 Check existence & effectiveness during design

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