Hi Hossam,
You will need to get copies of the relevant standards & the FSSC 22000 Certification Scheme requirements:
ISO 22000 Food safety management systems - Requirements for any organization in the food chain
TS ISO 22002 Prerequisite programmes on food safety Part 1: Food manufacturing
FSSC 22000 Additional Requirements
You will need to ensure you meet the requirements of ISO 22000 for food safety management systems, sections include 4 Food safety management system, 5 Management responsibility, 6 Resource management, 7 Planning and realization of safe products & 8 Validation, verification and improvement of the food safety management system. You will also need to ensure that the prescribed prerequisites are implemented and take a new approach to your HACCP as per ISO 22000 requirements with the main difference being the requirement to consider Operational Prerequisite Programmes.
Prerequisites are described in ISO 22000 Clause 7.2.3:
When selecting and/or establishing PRP(s), the organization shall consider and utilize appropriate information [e.g. statutory and regulatory requirements, customer requirements, recognized guidelines, Codex Alimentarius Commission (Codex) principles and codes of practices, national, international or sector standards]. NOTE Annex C gives a list of relevant Codex publications.
The organization shall consider the following when establishing these programmes:
a) construction and lay-out of buildings and associated utilities;
b) lay-out of premises, including workspace and employee facilities;
c) supplies of air, water, energy and other utilities;
d) supporting services, including waste and sewage disposal;
e) the suitability of equipment and its accessibility for cleaning, maintenance and preventative maintenance;
f) management of purchased materials (e.g. raw materials, ingredients, chemicals and packaging), supplies (e.g. water, air, steam and ice), disposals (e.g. waste and sewage) and handling of products (e.g. storage and transportation);
g) measures for the prevention of cross contamination;
h) cleaning and sanitizing;
i) pest control;
j) personnel hygiene;
k) other aspects as appropriate.
For the purposes of FSSC 22000 TS ISO 22002 is also relevant and this describes the following prerequisites:
This Technical Specification specifies detailed requirements to be specifically considered in relation to ISO 22000:2005, 7.2.3:
a) construction and layout of buildings and associated utilities;
b) layout of premises, including workspace and employee facilities;
c) supplies of air, water, energy and other utilities;
d) supporting services, including waste and sewage disposal;
e) suitability of equipment and its accessibility for cleaning, maintenance and preventive maintenance;
f) management of purchased materials;
g) measures for the prevention of cross-contamination;
h) cleaning and sanitizing;
i) pest control;
j) personnel hygiene.
In addition, this Technical Specification ISO 22002 adds other aspects which are considered relevant to manufacturing operations:
1) rework;
2) product recall procedures;
3) warehousing;
4) product information and consumer awareness;
5) food defence, biovigilance and bioterrorism.
So prerequisite programmes are put in place prior to Hazard Analysis (ISO 22000 Clause 7.4).
When you come to Clause 7.4.3 Hazard assessment onwards you will need to decide if control measures for a hazard fall into the category of needing to be controlled through operational PRP(s) or by the HACCP plan.
Clause 7.4.4 Selection and assessment of control measures elaborates further:
The selection and categorization shall be carried out using a logical approach that includes assessments with regard to the following:
a) its effect on identified food safety hazards relative to the strictness applied;
b) its feasibility for monitoring (e.g. ability to be monitored in a timely manner to enable immediate corrections);
c) its place within the system relative to other control measures;
d) the likelihood of failure in the functioning of a control measure or significant processing variability;
e) the severity of the consequence(s) in the case of failure in its functioning;
f) whether the control measure is specifically established and applied to eliminate or significantly reduce the level of hazard(s);
g) synergistic effects (i.e. interaction that occurs between two or more measures resulting in their combined effect being higher than the sum of their individual effects).
Control measures categorized as belonging to the HACCP plan shall be implemented in accordance with 7.6. Other control measures shall be implemented as operational PRPs according to 7.5.
An operational PRP is defined in ISO 22000:2005 as a prerequisite (PRP) identified by the hazard analysis as essential in order to control the likelihood of introducing food safety hazards to and/or the contamination or proliferation of food safety hazards in the product(s) or in the processing environment.
The requirements for OPRPs are prescribed in clause 7.5 Establishing the operational prerequisite programmes (PRPs)
The operational PRPs shall be documented and shall include the following information for each programme:
a) food safety hazard(s) to be controlled by the programme (see 7.4.4);
b) control measure(s) (see 7.4.4);
c) monitoring procedures that demonstrate that the operational PRPs are implemented;
d) corrections and corrective actions to be taken if monitoring shows that the operational PRPs are not in control (see 7.10.1 and 7.10.2, respectively);
e) responsibilities and authorities;
f) record(s) of monitoring.
Regards,
Tony
