(ISO TS 22002-1) Guidelines of implementing

As additional guidance for the food manufacturing organizations to comply for prerequisite programs, ISO has published this technical specification, ISO/TS 22002-1. Non GFSI ISO 22000 and extensive GFSI recognized standards as FSSC 22000, BRC Food, and IFS Food requires that the organization establishes PRP programs to control the likelihood of introducing contamination through the work environment based on the nature of the food manufacturing, according to ISO TS 22002-1 which was PAS 220 previously. The technical standard of ISO TS 22002-1 leaves the responsibility for developing the details of the program to the organization; since it does not give specific requirements for the certain aspects of PRPs, which the organization to determine what is appropriate. Major considerations of the ISO TS 22002-1 as follows;

 Construction and layout of buildings

ISO TS 22002-1 demands to have Buildings designed, constructed and maintained in a manner appropriate to the nature of the processing operations to be carried out, the food safety hazards associated with those operations and the potential sources of contamination from the plant environs while durability of the construction which presents no hazard to the product. Also under this clause food manufacturing organization need to give consideration to potential sources of contamination from the local environment. Food production not to be carried out in areas where potentially harmful substances could enter the product considered under environmental requirements. The effectiveness of measures taken to protect against potential contaminants need to be periodically reviewed, while site boundaries are clearly identified, access to the site controlled, and site maintained in good order. Vegetation at the facility to be tended or removed to prevent pest harborage as roosting birds. Roads, yards and parking areas need to design as they drained to prevent standing water and shall be maintained as per the Locations of establishment’s requirements.

Layout of premises and workspace

Internal layouts need to 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 designed to protect against potential contamination sources considered as the general requirements. The buildings shall provide adequate space, with a logical flow of materials, products and personnel, and physical separation of raw from processed areas comes as internal design, layout and traffic patterns. Examples of physical separation include walls, barriers or partitions, or sufficient distance to minimize risk. Openings intended for transfer of materials shall be designed to minimize entry of foreign matter and pests. Process area walls and floors shall be washable or cleanable, as appropriate for the process or product hazard. Materials of construction shall be resistant to the cleaning system applied. Wall floor junctions and corners shall be designed to facilitate cleaning. It is recommended that wall floor junctions be rounded in processing areas. Floors shall be designed to avoid standing water. In wet process areas, floors shall be sealed and drained. Drains shall be trapped and covered. Ceilings and overhead fixtures shall be designed to minimize build-up of dirt and condensation. External opening windows, roof vents or fan, where present, shall be insect screened. External opening doors shall be closed or screened when not in use are under the internal structures and fittings. Equipment shall be designed and located so as to facilitate good hygiene practices and monitoring. Equipment shall be located to permit access for operation, cleaning and maintenance comes under the Location of equipment requirement. In-line and on-line test facilities shall be controlled to minimize risk of product contamination. Microbiology laboratories shall be designed, located and operated so as to prevent contamination of people, plant and products. They shall not open directly on to a production area. Temporary structures shall be designed, located and constructed to avoid pest harbourage and potential contamination of products. Additional hazards associated with temporary structures and vending machines shall be assessed and controlled. Facilities used to store ingredients, packaging and products shall provide protection from dust, condensation, drains, waste and other sources of contamination. Storage areas shall be dry and well ventilated. Monitoring and control of temperature and humidity shall be applied where specified. Storage areas shall be designed or arranged to allow segregation of raw materials, work in progress and finished products. All materials and products shall be stored off the floor and with sufficient space between the material and the walls to allow inspection and pest control activities to be carried out. The storage area shall be designed to allow maintenance and cleaning, prevent contamination and minimize deterioration. A separate, secure (locked or otherwise access controlled) storage area shall be provided for cleaning materials, chemicals and other hazardous substances. Exceptions for bulk or agricultural crop materials shall be documented in the food safety management system.

 Utilities — air, water, energy

The provision and distribution routes for utilities to and around processing and storage areas shall be designed to minimize the risk of product contamination. Utilities’ quality shall be monitored to minimize product contamination risk. The supply of potable water shall be sufficient to meet the needs of the production process(es). Facilities for storage, distribution and, where needed, temperature control of the water shall be designed to meet specified water quality requirements. Water used as a product ingredient, including ice or steam (including culinary steam), or in contact with products or product surfaces, shall meet specified quality and microbiological requirements relevant to the product. Water for cleaning or applications where there is a risk of indirect product contact (e.g. jacketed vessels, heat exchangers) shall meet specified quality and microbiological requirements relevant to the application. Where water supplies are chlorinated, checks shall ensure that the residual chlorine level at the point of use remains within limits given in relevant specifications. Non-potable water shall have a separate supply system that is labelled and not connected to the potable water system. Take measures to prevent non-potable water refluxing into the potable system. It is recommended that water that can come into contact with the product should flow through pipes that can be disinfected. Boiler chemicals, if used, shall be either approved food additives which meet relevant additive specifications; or additives which have been approved by the relevant regulatory authority as safe for use in water intended for human consumption. Boiler chemicals shall be stored in a separate, secure (locked or otherwise access-controlled) area when not in immediate use. The organization shall establish requirements for filtration, humidity (RH%) and microbiology of air used as an ingredient or for direct product contact. Where temperature and/or humidity are deemed critical by the organization, a control system shall be put in place and monitored. Ventilation (natural or mechanical) shall be provided to remove excess or unwanted steam, dust and odours, and to facilitate drying after wet cleaning. Room air supply quality shall be controlled to minimize risk from airborne microbiological contamination. Protocols for air quality monitoring and control shall be established in areas where products which support the growth or survival of microorganisms are exposed. Ventilation systems shall be designed and constructed such that air does not flow from contaminated or raw areas to clean areas. Specified air pressure differentials shall be maintained. Systems shall be accessible for cleaning, filter changing and maintenance. Exterior air intake ports shall be examined periodically for physical integrity. Compressed air, carbon dioxide, nitrogen and other gas systems used in manufacturing and/or filling shall be constructed and maintained so as to prevent contamination. Gases intended for direct or incidental product contact (including those used for transporting, blowing or drying materials, products or equipment) shall be from a source approved for food contact use, filtered to remove dust, oil and water. Where oil is used for compressors and there is potential for the air to come into contact with the product, the oil used shall be food grade. Use of oil free compressors is recommended. Requirements for filtration, humidity (RH%) and microbiology shall be specified. Filtration of the air should be as close to the point of use as is practicable. The lighting provided (natural or artificial) shall allow personnel to operate in a hygienic manner. The intensity of the lighting should be appropriate to the nature of the operation. Light fixtures shall be protected to ensure that materials, product or equipment are not contaminated in the case of breakages.

 Waste disposal

Systems to be in place to ensure that waste materials are identified, collected, removed and disposed of in a manner which prevents contamination of products or production areas. Containers for waste and inedible or hazardous substances shall be clearly identified for their intended purpose, located in a designated area, constructed of impervious material which can be readily cleaned and sanitized, closed when not in immediate use, and locked where the waste may pose a risk to the product. Containers for waste and inedible or hazardous substances. Provision shall be made for the segregation, storage and removal of waste. Accumulation of waste shall not be allowed in food-handling or storage areas. Removal frequencies shall be managed to avoid accumulations, with a minimum daily removal. Labelled materials, products or printed packaging designated as waste shall be disfigured or destroyed to ensure that trademarks cannot be reused. Removal and destruction shall be carried out by approved disposal contractors. The organization shall retain records of destruction. Drains shall be designed, constructed and located so that the risk of contamination of materials or products is avoided. Drains shall have capacity sufficient to remove expected flow loads. Drains shall not pass over processing lines. Drainage direction shall not flow from a contaminated area to a clean area.

 Equipment suitability, cleaning and maintenance

Food contact equipment shall be designed and constructed to facilitate cleaning, disinfection and maintenance. Contact surfaces shall not affect, or be affected by, the intended product or cleaning system. Food contact equipment shall be constructed of durable materials able to resist repeated cleaning as general requirements. Equipment shall be able to meet established principles of hygienic design, including, smooth, accessible, cleanable surfaces, self draining in wet process areas, use of materials compatible with intended products and cleaning or flushing agents, framework not penetrated by holes or nuts and bolts. Piping and ductwork shall be cleanable, drainable, and with no dead ends. Equipment shall be designed to minimize contact between the operator’s hands and the products. Product contact surfaces shall be constructed from materials designed for food use. They shall be impermeable and rust or corrosion free. Equipment used for thermal processes shall be able to meet the temperature gradient and holding conditions given in relevant product specifications. Equipment shall provide for the monitoring and control of the temperature. Wet and dry cleaning programmes shall be documented to ensure that all plant, utensils and equipment are cleaned at defined frequencies. The programmes shall specify what is to be cleaned (including drains), the responsibility, and the method of cleaning (e.g. CIP, COP), the use of dedicated cleaning tools, removal or disassembly requirements and methods for verifying the effectiveness of the cleaning. A preventive maintenance programme shall be in place. The preventive maintenance programme shall include all devices used to monitor and/or control food safety hazards. Examples of such devices include screens and filters (including air filters), magnets, metal detectors and X-ray detectors. Corrective maintenance shall be carried out in such a way that production on adjoining lines or equipment is not at risk of contamination. Maintenance requests which impact 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 maintenance schedule. Lubricants and heat transfer fluids shall be food grade where there is a risk of direct or indirect contact with the product. The procedure for releasing maintained equipment back to production shall include clean up, sanitizing, where specified in process sanitation procedures, and pre-use inspection. Local area PRP requirements shall apply to maintenance areas and maintenance activities in process areas. Maintenance personnel shall be trained in the product hazards associated with their activities.

 Management of purchased materials

Purchasing of materials which impact food safety shall be controlled to ensure that the suppliers used have the capability to meet the specified requirements. The conformance of incoming materials to specify purchase requirements shall be verified comes as general requirements. There shall be a defined process for the selection, approval and monitoring of suppliers. The process used shall be justified by hazard assessment, including the potential risk to the final product, and shall include: assessment of the supplier’s ability to meet quality and food safety expectations, requirements and specifications; description of how suppliers are assessed; Examples of a description of how suppliers are assessed include: audit of the supplying site prior to accepting materials for production; appropriate third party certification, monitoring the performance of the supplier to assure continued approval status. Monitoring includes conformity with material or product specifications, fulfilment of COA requirements, satisfactory audit outcomes. Delivery vehicles shall be checked prior to, and during, unloading to verify that the quality and safety of the material has been maintained during transit (e.g. integrity of seals, freedom from infestation, existence of temperature records). Materials shall be inspected, tested or covered by COA to verify conformity with specified requirements prior to acceptance or use. The method of verification shall be documented. The inspection frequency and scope can be based on the hazard presented by the material and the risk assessment of the specific suppliers. Materials which do not conform to relevant specifications shall be handled under a documented procedure which ensures they are prevented from unintended use. Access points to bulk material receiving lines shall be identified, capped and locked. Discharge into such systems shall take place only after approval and verification of the material to be received are the Incoming material requirements (raw/ingredients/packaging)

Measures for prevention of cross-contamination

Programmes shall be in place to prevent, control and detect contamination. Measures to prevent physical, allergen and microbiological contamination shall be included. Areas where potential for microbiological cross-contamination exists (airborne or from traffic patterns) shall be identified and a segregation (zoning) plan implemented. A hazard assessment shall be carried out to determine potential contamination sources, susceptibility of the product and control measures suitable for these areas as; separation of raw from finished or ready to eat (RTE) products, structural segregation — physical barriers, walls or separate buildings, access controls with requirements to change into required workwear, traffic patterns or equipment segregation — people, materials, equipment and tools (including use of dedicated tools), air pressure differentials. Allergens present in the product, either by design or by potential manufacturing cross-contact, shall be declared. The declaration shall be on the label for consumer products, and on the label or the accompanying documentation for products intended for further processing. Products shall be protected from unintended allergen cross-contact by cleaning and line change-over practices and/or product sequencing. Manufacturing cross-contact can arise from either; traces of product from the previous production run which cannot be adequately cleaned from the product line due to technical limitations; or when contact is likely to occur, in the normal manufacturing process, with products or ingredients that are produced on separate lines, or in the same or adjacent processing areas. Rework containing allergen(s) shall be used only; in products which contain the same allergen(s) by design; or through a process which is demonstrated to remove or destroy the allergenic material. Employees handling food should receive specific training in allergen awareness and associated manufacturing practices. Where brittle materials are used, periodic inspection requirements and defined procedures in case of breakage shall be put in place. Brittle materials, such as glass and hard plastic components in equipment, should be avoided where possible. Glass breakage records shall be maintained. Based on hazard assessment, measures shall be put in place to prevent, control or detect potential contamination. Physical contamination Examples of such measures include; adequate covers over equipment or containers for exposed materials or products, use of screens, magnets, sieves or filters, use of detection or rejection devices such as metal detectors or X-ray, Sources of potential contamination include wooden pallets and tools, rubber seals, and personal protective clothing and equipment.

Cleaning and sanitizing

Cleaning and sanitizing programmes shall be established to ensure that the food-processing equipment and environment are maintained in a hygienic condition. Programmes shall be monitored for continuing suitability and effectiveness. Facilities and equipment shall be maintained in a condition which facilitates wet or dry cleaning and/or sanitation. Cleaning and sanitizing agents and chemicals shall be clearly identified, food grade, stored separately and used only in accordance with the manufacturer’s instructions. Tools and equipment shall be of hygienic design and maintained in a condition which does not present a potential source of extraneous matter. Cleaning and sanitizing agents and tools. Cleaning and sanitizing programmes shall be established and validated by the organization to ensure that all parts of the establishment and equipment are cleaned and/or sanitized to a defined schedule, including the cleaning of cleaning equipment. Cleaning and/or sanitizing programmes shall specify at a minimum, areas, items of equipment and utensils to be cleaned and/or sanitized; responsibility for the tasks specified; cleaning/sanitizing method and frequency; monitoring and verification arrangements; post-clean inspections; pre start-up inspections. CIP systems shall be separated from active product lines. Parameters for CIP systems shall be defined and monitored (including type, concentration, contact time and temperature of any chemicals used). Cleaning and sanitation programmes shall be monitored at frequencies specified by the organization to ensure their continuing suitability and effectiveness.

Pest control

Hygiene, cleaning, incoming materials inspection and monitoring procedures shall be implemented to avoid creating an environment conducive to pest activity. The establishment shall have a nominated person to manage pest control activities and/or deal with appointed expert contractors. Pest management programmes shall be documented and shall identify target pests, and address plans, methods, schedules, control procedures and, where necessary, training requirements. Programmes shall include a list of chemicals which are approved for use in specified areas of the establishment.

Buildings shall be maintained in good repair. Holes, drains and other potential pest access points shall be sealed. External doors, windows or ventilation openings shall be designed to minimize the potential for entry of pests. Storage practices shall be designed to minimize the availability of food and water to pests. Material found to be infested shall be handled in such a way as to prevent contamination of other materials, products or the establishment. Potential pest harbourage (e.g. burrows, undergrowth, stored items) shall be removed. Where outside space is used for storage, stored items shall be protected from weather or pest damage (e.g. bird droppings). Harbourage and infestations. Pest-monitoring programmes shall include the placing of detectors and traps in key locations to identify pest activity. A map of detectors and traps shall be maintained. Detectors and traps shall be designed and located so as to prevent potential contamination of materials, products or facilities. Detectors and traps shall be of robust, tamper-resistant construction. They shall be appropriate for the target pest. The detectors and traps shall be inspected at a frequency intended to identify new pest activity. The results of inspections shall be analysed to identify trends. Eradication measures shall be put in place immediately after evidence of infestation is reported. Pesticide use and application shall be restricted to trained operatives and shall be controlled to avoid product safety hazards. Records of pesticide use shall be maintained to show the type, quantity and concentrations used; where, when and how applied, and the target pest.

Personnel hygiene and employee facilities

Requirements for personal hygiene and behaviours proportional to the hazard posed to the process area or product 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 to ensure that the degree of personal hygiene required by the organization can be maintained. The facilities shall be located close to the points where hygiene requirements apply and shall be clearly designated. Establishments shall; provide adequate numbers, locations and means of hygienically washing, drying and, where required, sanitizing hands (including wash-basins, supply of hot and cold or temperature controlled water, and soap and/or sanitizer); have sinks designated for hand washing, whose taps should not be hand operated, separate from sinks for food use and equipment-cleaning stations; provide an adequate number of toilets of appropriate hygienic design, each with hand-washing, drying and, where required, sanitizing facilities; have employee hygiene facilities that do not open directly on to production, packing or storage areas; have adequate changing facilities for personnel; have changing facilities sited to enable personnel handling food to move to the production area in such a way that risk to the cleanliness of their workwear is minimized. Staff canteens and designated areas for food storage and consumption shall be situated so that the potential for cross-contamination of production areas is minimized. Staff canteens shall be managed to ensure hygienic storage of ingredients and preparation, storage and serving of prepared foods. Storage conditions and storage, cooking and holding temperatures, and time limitations, shall be specified. Employees’ own food shall be stored and consumed in designated areas only. Personnel who work in, or enter into, areas where exposed products and/or materials are handled shall wear work clothing that is fit for purpose, clean and in good condition (e.g. free from rips, tears or fraying material). Clothing mandated for food protection or hygiene purposes shall not be used for any other purpose. Workwear shall not have buttons. Workwear shall not have outside pockets above waist level. Zips or press stud fastenings are acceptable. Workwear shall be laundered to standards and at intervals suitable for the intended use of the garments. Workwear shall provide adequate coverage to ensure that hair, perspiration, etc. cannot contaminate the product. Hair, beards, and moustaches shall be protected (i.e. completely enclosed) by restraints unless hazard analysis indicates otherwise. Where gloves are used for product contact, they shall be clean and in good condition. Use of latex gloves should be avoided where possible. Shoes for use in processing areas shall be fully enclosed and made from non-absorbent materials. Personal protective equipment, where required, shall be designed to prevent product contamination and maintained in hygienic condition. Workwear and protective clothing Subject to legal restrictions in the country of operation, employees shall undergo a medical examination prior to employment in food contact operations (including site catering), unless documented hazard or medical assessment indicates otherwise. Additional medical examinations, where permitted, shall be carried out at intervals defined by the organization. Where permitted by law, employees shall be required to report the following conditions to management for possible exclusion from food-handling areas: jaundice, diarrhoea, vomiting, and fever, sore throat with fever, visibly infected skin lesions (boils, cuts or sores) and discharges from the ear, eye or nose. People known or suspected to be infected with, or carrying, a disease or illness transmissible through food shall be prevented from handling food or materials which come into contact with food. In food-handling areas, personnel with wounds or burns shall be required to cover them with specified dressings. Any lost dressing shall be reported to supervision immediately. Dressings should be brightly coloured and metal detectable where appropriate. Personnel in food production areas shall be required to wash and, where required, sanitize hands; before starting any food-handling activities; immediately after using the toilet or blowing the nose; immediately after handling any potentially contaminated material. Personnel shall be required to refrain from sneezing or coughing over materials or products. Spitting (expectorating) shall be prohibited. Fingernails shall be kept clean and trimmed. A documented policy shall describe the behaviours required of personnel in processing, packing and storage areas. The policy shall at a minimum cover; permissibility of smoking, eating, chewing in designated areas only; control measures to minimize hazards presented by permitted jewellery, such as that worn by personnel in processing and storage areas, taking into account religious, ethnic, medical and cultural imperatives; permissibility of personal items, such as smoking materials and medicines, in designated areas only; prohibition of the use of nail polish, false nails and false eyelashes; prohibition of carrying of writing implements behind the ears; maintenance of personal lockers so that they are kept free from rubbish and soiled clothing; prohibition of storage of product contact tools and equipment in personal lockers.

Rework

Rework shall be stored, handled and used in such a way that product safety, quality, traceability and regulatory compliance are maintained. Stored rework shall be protected from exposure to microbiological, chemical or extraneous matter contamination. Segregation requirements for rework (e.g. allergen) shall be documented and met. Rework shall be clearly identified and/or labelled to allow traceability. Traceability records for rework shall be maintained. The rework classification or the reason for rework designation shall be recorded (e.g. product name, production date, shift, line of origin, shelf-life). Where rework is incorporated into a product as an “in-process” step, the acceptable quantity, type and conditions of rework use shall be specified. The process step and method of addition, including any necessary pre-processing stages, shall be defined. Where rework activities involve removing a product from filled or wrapped packages, controls shall be put in place to ensure the removal and segregation of packaging materials and to avoid contamination of the product with extraneous matter.

Product recall procedures

Systems shall be in place to ensure that products failing to meet required food safety standards can be identified, located and removed from all necessary points of the supply chain. A list of key contacts in the event of a recall shall be maintained. Where products are withdrawn due to immediate health hazards, the safety of other products produced under the same conditions shall be evaluated. The need for public warnings shall be considered.

Warehousing

Materials and products shall be stored in clean, dry, well-ventilated spaces protected from dust, condensation, fumes, odours or other sources of contamination. Effective control of warehousing temperature, humidity and other environmental conditions shall be provided where required by product or storage specifications. It is recommended that where products are stacked, consideration is given to measures necessary to protect the lower layers. Waste materials and chemicals (cleaning products, lubricants, and pesticides) shall be stored separately. A separate area or other means of segregating materials identified as non-conforming shall be provided. Specified stock rotation systems (FIFO/FEFO) shall be observed. Gasoline- or diesel-powered fork-lift trucks shall not be used in food ingredient or product storage areas. Vehicles, conveyances, and containers shall be maintained in a state of repair, cleanliness, and condition consistent with requirements given in relevant specifications. Vehicles, conveyances, and containers shall provide protection against damage or contamination of the product. Control of temperature and humidity shall be applied and recorded where required by the organization. Where the same vehicles, conveyances, and containers are used for food and non-food products, cleaning shall be carried out between loads. Bulk containers shall be dedicated to food use only. Where required by the organization, bulk containers shall be dedicated to a specified material.

Product information and consumer awareness

Information shall be presented to consumers in such a way as to enable them to understand its importance and make informed choices. Information may be provided by labelling or other means, such as company websites and advertisements, and may include storage, preparation and serving instructions applicable to the product.

 Food defence, biovigilance, and bioterrorism

Each establishment shall assess the hazard to products posed by potential acts of sabotage, vandalism or terrorism and shall put in place proportional protective measures. Potentially sensitive areas within the establishment shall be identified, mapped, and subjected to access control. Where feasible, access should be physically restricted by use of locks, electronic card key or alternative systems. 

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