Chapter 3-PRP-ISO - TS 22002-1 and Additional Req

AWARENESS & APPLICATION FOR INTEGRATED MANAGEMENT SYSTEM
ISO 9001:2015 & FSSC 22000 VER. 5.1
Tutor : Mr. Nguyen Dai Hiep

Food Lead Tutor/ Auditor
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Valuation and Confidence
Chapter 3: Overview PRP- ISO/TS 22002-1 and added

requirements from FSSC
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ISO/TS 22002-1 Requirements
Contents of ISO/TS 22002-1
► § 1 Scope
► § 2 Normative reference
► § 3 Terms & definitions
► § 4 Construction and layout of buildings
► § 5 Layout of premises and workspace
► § 6 Utilities – air, water, energy
► § 7 Waste disposal
REQUIREMENTS
► § 8 Equipment suitability, cleaning and maintenance

► § 9 Management of purchased materials
► § 10 Measures for prevention of cross contamination
► § 11 Cleaning and sanitizing
► § 12 Pest control
► § 13 Personnel hygiene and employee facilities
► § 14 Rework
► § 15 Product recall procedure
► § 16 Warehousing
► § 17 Product information / consumer awareness
► § 18 Food defence, biovigilance and bioterrorism
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Terms & definitions

► ISO 22000 § 3 applies with some extra terms
► Codex Alimentarius used as a guidance for definitions
► § 3.2 contaminant: is not intentionally added to food;

another PAS (# 96) is dealing food defence. But see § 18
► § 3.4 materials: not only raw material but also for
packaging, process aids, cleaning chemical and
lubricants
► § 3.12 sanitizing = cleaning + disinfection
► § 3.15 zoning: taking into account microbiological cross-
contamination to define & segregate areas
► § 3.18 & 3.19: FEFO ≠ FIFO
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Foreword
► Shall = must
► Should = recommendation
► NOTE = is not compulsory (same as ISO 22000)
► Usually, each chapter begins with a “statement of intent”

(as BRC standards) explaining the main objectives of the
requirement – General Requirements
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4 Construction and layout of buildings

► 4.1 What to do if buildings are old, haven’t been designed for the
current purpose but some adequate improvement & fixing have been
implemented?
► 4.2
 Give example of possible contamination from the local environment.

 Give some examples of control measure against above
contamination?
 What is the appropriate frequency for reviewing the effectiveness of
these control measures?
 How to keep record that consideration has been given about this
issue?
► 4.3 How to control access to the site?
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5 Layout of premises and workspace
► 5.1 How to assess this clause?
► 5.2 If physical separation is not possible due to lack of space,

but a time “separation” is implemented, is it compliant?
► 5.3
 What to do as an auditor if wall floor junction are not

rounded?
 What to do as an auditor if some water is remaining on the
production workshop?
 Is it possible to open external windows during manufacturing
hours?
► 5.4 What is the appropriate distance between an equipment and
the walls?
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5 Layout of premises and workspace (cont’d)
► 5.5
 Is on-line temperature checks with a glass thermometer OK?

 If the laboratory is not testing for pathogenic micro-organisms but
only Total count shall it still be separated from production area?
► 5.6 What kind of additional hazards can be associated with vending
machines?
► 5.7
 How often to monitor temperature & humidity?

 No pallets along the walls!
 Is it possible to store grain directly on the floor?
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6 Utilities – air, water, energy

► 6.1
 Minimizing contamination
 Beware of leaks, dirty pipes over products…
 Utilities not to contaminate the product (ex: oil-free compressed air)
► 6.2
 Potable water: according to WHO & local regulation

 Is it sufficient to provide a water analysis coming from municipal
network?
 How often testing water for microbiological & chemical criteria?
 Water chlorination to be closely monitored at the point of use
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6 Utilities – air, water, energy cont’d

► 6.3 “Approved food additives” boiler chemical to be used
► 6.4
 Provide examples of air used as an ingredient

 Is microbiological analysis of air demanded in every cases?
 How often testing air for microbiology?
 Provide examples where air temperature / humidity is critical
 Are positive air pressure system compulsory?
 Air filtration system to be included in cleaning & preventive
maintenance schedule
 How to periodically inspect exterior air intake ports?
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6 Utilities – air, water, energy cont’d

► 6.5
 “Food grade” gases (NO2, CO2)
 Compressed air to be filtered & with oil remove system
 Shall all compressors be using “food grade” oil?
► 6.6
 Where to protect lighting in case of breakage?
 How to protect lighting in case of breakage?
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7 Waste disposal
► 7.1 Statement of intent: prevent contamination
► 7.2
 Dedicated containers for waste, hazardous substances

 Containers to be clearly identified closed/ locked
► 7.3
 How often to remove waste?

 Is it forbidden to have a waste bin in production area?
 Why this clause about trademark destruction to be recorded?
► 7.4
 Why drain shall not pass over production line?

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8 Equipment suitability, cleaning & maintenance

► 8.1 Statement of intent: no contamination & easy to clean
► 8.2 Principles of equipment hygienic design

(ISO 14159:2002)
► 8.3
 What shall an auditor be asking to check that product contact surfaces are
of “food grade”?
 How to ensure that equipment prior 2004 is suitable for food?
► 8.4
 Provide examples of equipment used for thermal processes

 ≈ process or equipment validation
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8 Equipment suitability, cleaning & maintenance (cont’d)
► 8.5
 What shall be mentioned on a documented cleaning programme?

 Don’t forget utensils, air filtration / cooling equipment
 Is verification of cleanliness compulsory?
 How to verify effectiveness of the cleaning?
► 8.6
 Corrective maintenance not sufficient: preventive is demanded!

 How to avoid contamination during maintenance operations?
 Beware of temporary repairs (tape…) & lubricants
 Positive release of equipment after repair is demanded & to be recorded
 Maintenance personnel to be trained on relevant food safety hazards
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9 Management of purchased material
► 9.1 Statement of intent: ensure supplier capability to provide safe material
& verify purchased material is safe
► 9.2
 ≈ ISO 9001 but focusing on food safety, based on hazard assessment

 Is auditing of suppliers compulsory?
 Provide example of performance criteria to be defined & followed?
► 9.3
 Prior unloading checks

 How often to test incoming materials?
 Why access points to bulk material must be locked?
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10 Measures for prevention of cross contamination

► 10.1 Statement of intent & scope
► 10.2
 Zoning to be defined & implemented using hazard analysis

 Beware of movement of personnel, waste, utilities and tools
 In which case as an auditor you would demand for a positive air pressure
system?
► 10.3
 Which allergens shall be considered? Declared?

 Rework to be closely assessed
 Personnel handling allergens to be trained
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10 Measures for prevention of cross contamination (cont’d)
► 10.4
 How often to inspect glass & hard plastic material?
 Why recording glass breakage?
 Specific attention to be paid on: screens, magnets, sieves, filters,
metal detector, wooden pallets, protective clothing…
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11 Cleaning and sanitizing

► 11.1 Statement of intent: establish and monitor programmes
► 11.2
 “Food grade” cleaning chemical to be used

 Cleaning equipment and utensils to be in good repair
► 11.3
 How to validate cleaning & sanitizing programmes?

 Are post-cleaning & pre start-up inspections compulsory?
► 11.4 CIP to be monitored
► 11.5 How to check sanitation effectiveness? How often?
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12 Pest control
► 12.1 Statement of intent
► 12.2
 Mr. Pest to be nominated

 What to mention in pest control programmes?
 List of chemicals and there approval.
 Are poisonous baits forbidden in production area?
► 12.3 To prevent pest ingress: no holes, sealed drains, screened windows,
proof fit doors…
► 12.4 Implement good storage practices
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12 Pest control (cont’d)

► 12.5
 Updated map of baits including fly killers

 How often to inspect baits?
 Records shall be analyzed - trends
 If sub-contracted all requirements still apply
► 12.6
 Use and application restrict to trained operatives

 Pesticide to be approved as can be used in food processing area
 Comprehensive records to be maintained
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13 Personnel hygiene and employee facilities

► 13.1 Statement of intent: document appropriate requirements to personnel, visitors
(auditors…) & contractors
► 13.2
 In which cases, is hand sanitizing required?

 Supply of cold and hot water or temperature controlled
 Toilets shall not open directly on to production, packaging or storage areas
► 13.3
 Canteen and designated areas shall not bring contamination to product

 Hygienic storage, cooking and holding temperatures
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13 Personnel hygiene and employee facilities (cont’d)

► 13.4
 Workwear in good conditions

 No buttons, no pockets above waist
 What is the appropriate interval for laundry?
 Is home laundry acceptable?
 Hair but also beards & moustaches to be contained
 Look at the shoes
► 13.5
 Medical screening required prior to employment

 What is the appropriate frequency for on-going medical screening?
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13 Personnel hygiene and employee facilities (cont’d)

► 13.6
 List of illnesses / symptoms

 Wounds preferably covered by dressings (colored and metal detectable)
 Also applies to visitors & contractors
► 13.7 Detailed requirements for personnel cleanliness
► 13.8
 Documented Policy
 Jewellery to be considered as a hazard
 False nails & nail polish forbidden
 Look at what’s inside personal locker and above!
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14 Rework
► 14.1 Statement of intent: rework shall not jeopardize product safety, quality, legality
and traceability
► 14.2 Rework to be
 Adequately stored & labeled

 Recorded to maintain traceability
► 14.3
 Reworking rule to be defined: recipe A in recipe B, shelf life, storage conditions…

and mentioned on flow diagram
 Reworking rules to be validated: shelf life, labelling of finished products
 Prevent contamination if unpacking step
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15 Product recall procedures

► 15.1 Statement of intent: being able to identify, locate and remove all
unsafe/non conforming product along the supply chain
► 15.2
 Detailed procedure including key contacts

 Who are the key contacts in case of product recall?
 Consider public warning
 Consider products manufactured according to similar conditions
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16 Warehousing
► 16.1 Statement of intent: storage conditions shall not contaminate products
► 16.2
 How often to monitor storage conditions (temperature / humidity)?

 Non conforming products to be segregated
 FEFO or FIFO system to be implemented
 Use of diesel or gasoline powered fork lift trucks forbidden everywhere?
► 16.3
 Is permanent recording of vehicles temperature compulsory?

 Beware of bulk transportation – Food use only
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17 Product information and consumer awareness

► Information shall be present in a way that the consumer to choose products with full
knowledge of relevant information
► Information can be provided by labeling, websites and ads
 Relevant allergens mentioned?

 Shelf life mentioned?
 Batch number mentioned?
 Appropriate language?
 Conditions of use described?
 Customer care contact mentioned? Preparation and serving
 Any other relevant data…
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18 Food defence, biovigilance and bioterrorism

► 18.1
 Intentional contamination shall be considered during hazard analysis

 Protective measure to be implemented accordingly (tamper evident packaging,
locked silos, personnel background screening…)
► 18.2
 What are the sensitive areas?

 How to control access?
 If external doors are kept open?
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Additional Requirements by FSSC 22000 Ver 5.1
Refer to 2.5 of FSSC 22000 Scheme version 5.1
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Additional Requirements, Ver 5.1
►The additional Scheme requirements are: Refer part 2, 2.5

2.5.1) Management of services and purchased materials {a,b,c,d}
2.5.2) Product labelling,
2.5.3) Food defense,
2.5.4) Food fraud mitigation,
2.5.5) Logo use,
2.5.6) Management of allergens (for categories C, I and K only),
2.5.7) Environmental monitoring (for categories C, I and K only),
2.5.10) Storage and warehousing
2.5.12) PRP verification.
2.5.13) Product development
Are you available for these in your factory?

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HOW TO APPLY FOOD SAFETY CULTURE
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I HOW TO APPLY FOOD SAFETY CULTURE
1. Plan and implemet internal audit ( Ref. audit checklist for food safety culture)….>>>
making audit report
2. Survey 1- Gerenal questions to all employees

3. Survey 2- Awereness questions for quality and food safey to leaders, supervisors,
technical man, QA/QC
….>>>> making the report base on comparision with annex of food safety guide….>>>
comments and suggestions for improving human resource
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AWARENESS & APPLICATION FOR INTEGRATED MANAGEMENT SYSTEM

ISO 9001:2015 & FSSC 22000 VER. 5.1

Tutor : Mr. Nguyen Dai Hiep

Valuation and Confidence

Chapter 3: Overview PRP- ISO/TS 22002-1 and added

► § 8 Equipment suitability, cleaning and maintenance

ISO/TS 22002-1 Requirements

Terms & definitions

► Codex Alimentarius used as a guidance for definitions

► § 3.2 contaminant: is not intentionally added to food;

► NOTE = is not compulsory (same as ISO 22000)

► Usually, each chapter begins with a “statement of intent”

ISO/TS 22002-1 Requirements

4 Construction and layout of buildings

 Give example of possible contamination from the local environment.

► 5.2 If physical separation is not possible due to lack of space,

 What to do as an auditor if wall floor junction are not

ISO/TS 22002-1 Requirements

 Is on-line temperature checks with a glass thermometer OK?

 How often to monitor temperature & humidity?

6 Utilities – air, water, energy

 Potable water: according to WHO & local regulation

ISO/TS 22002-1 Requirements

6 Utilities – air, water, energy cont’d

 Provide examples of air used as an ingredient

6 Utilities – air, water, energy cont’d

ISO/TS 22002-1 Requirements

 Dedicated containers for waste, hazardous substances

 How often to remove waste?

 Why drain shall not pass over production line?

8 Equipment suitability, cleaning & maintenance

► 8.2 Principles of equipment hygienic design

 Provide examples of equipment used for thermal processes

ISO/TS 22002-1 Requirements

 What shall be mentioned on a documented cleaning programme?

 Corrective maintenance not sufficient: preventive is demanded!

 ≈ ISO 9001 but focusing on food safety, based on hazard assessment

 Prior unloading checks

ISO/TS 22002-1 Requirements

10 Measures for prevention of cross contamination

 Zoning to be defined & implemented using hazard analysis

 Which allergens shall be considered? Declared?

10 Measures for prevention of cross contamination (cont’d)

ISO/TS 22002-1 Requirements

11 Cleaning and sanitizing

 “Food grade” cleaning chemical to be used

 How to validate cleaning & sanitizing programmes?

► 11.5 How to check sanitation effectiveness? How often?

 Mr. Pest to be nominated

ISO/TS 22002-1 Requirements

12 Pest control (cont’d)

 Updated map of baits including fly killers

 Use and application restrict to trained operatives

13 Personnel hygiene and employee facilities

 In which cases, is hand sanitizing required?

 Canteen and designated areas shall not bring contamination to product

ISO/TS 22002-1 Requirements

13 Personnel hygiene and employee facilities (cont’d)

 Workwear in good conditions

 Medical screening required prior to employment

13 Personnel hygiene and employee facilities (cont’d)

 List of illnesses / symptoms

ISO/TS 22002-1 Requirements