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Example of use for oPRP?

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Posted 16 May 2007 - 02:41 PM


I'm new at this forum.

I work at a company which produces juice concentrates among other things. Altogether we have several hundred products so it would be too voluminous to create a hazard analysis for each single product. So it is done for the processes like the different production lines.

Until now, the noticed hazards that are not CCP are written down as Control Points.

My task is to combine measures to create PRP’s and oPRP’s.

I have a few questions regarding oPRP:

- unlike Control Points which are monitored and controlled at one point of the process I understand oPRP’s to be a program. But what exactly does that mean?

- example: CP:

o the process step labelling (occurring e.g. at the processes preparation and filling) holds a chemical hazard because of missing or wrong declaration and because of that possible misused material

o monitoring: sight check the declaration by educated employees

o corrective action: information to supervisor who acts as the situation needs it

- questions:

o Can I convert this CP completely into an oPRP?

o How can I validate and/or verify “sight check”? How can I combine it with other actions?

I would be very thankful if anybody could help me out on that!

Thanks in advance!



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Posted 19 May 2007 - 08:26 AM

Hi Agleh and welcome to the forum.

Interesting questions.
Although I’m not a user of I22k myself, I can offer some comments to yr questions so that other actual users may freely criticise (preferably constructively :smile: ).

“Program”. Well, I22k defines PRP (3.8) as (food safety) basic conditions and activities that are necesssary ……. – This seems helpfully flexible.
However the format for the oPRP program has more exact required inclusions, see para7.5 (a-f) (sort of mini-CCP I guess).

A previous thread contained this (slightly shortened by me) description of PRP and oPRP which seemed quite useful IMO (credit Sonali) –

“PRP : These are basically the generic controls in any type of food buisness operation.. These are to be applied in all types of food buisness so as to maintain a hygienic environment to reduce the risk to the Food Safety .
Eg - Plant Layout or infrastructure control , pest control, personnel hygiene, sanitation , work environment.
PRP are foundation of HACCP .

oPRP : These differ from PRP in the sense that these are SPECIFIC to particular industry /food operations . And these are arrived only after doing the hazard analysis. So, oPRP wil differ within the food industry while PRP could be more or less similiar. Therefore, after you conduct hazard analysis for a specific food chain and there comes a requirement/step where control is required to prevent /reduce the hazard it becomes oPRP .

CCP : CCP also arrive as a result of Hazard Aanlysis but difference b/w oPRP & CCP is the risk level of the identified hazard. If the hazard pose very high risk to food safety then it is CCP rather than oPRP(substantial risk) .
Also, while doing hazard analysis some steps are required to control the hazard but since the hazard is reduced /eliminated in further step , it is not considered a CCP , so in such case it's an oPRP"

Since you have ‘done” HACCP already I guess you must already have compiled a set of procedures like SSOP typically derived from GMP, GAP etc. Depending on yr facility (eg see 7.2.2), I would hope the” procedures” in this to be similar to the desired “programs” for I22k”s PRP (“Maintenance and Infrastructure) but requiring further additions as per 7.2.3 maybe.

Regarding the choice as to the appropriate risk classification for CCP / oPRP, this may depend on the methodology within yr existing HACCP plan. One approach is illustrated here –

http://www.nordicinn..._img/heggum.pdf (pg 11)

Yr label question.
(Actually in some cases I have seen labeling as a CCP [eg for allergen or for reasons of traceability.] Currently it seems popular to put the former within HACCP prerequisite programs and separate the latter to itself.)
Auditors IMEX do not accept mislabelling other than allergenic related as a significant safety risk so IMO would not be an oPRP. Other people have any ideas on this ?
If you can justify otherwise, you need to satisfy para7.5 at a minimum.

“Validate sight check”? Devise a challenge test perhaps? Optician’s record.? :biggrin:
“Verification”? – Monitoring records ?? Maybe post-packaging sampling/checking? Complaints file?

Pls come back if more info required.

Rgds / Charles.C

Added – had some more thoughts about labelling.
After looking at link above, I realised that even the lowest risk was still designated as oPRP. I also noticed that 7.4.4 states that all control measures categorised as not belonging to the HACCP plan (ie non-CCPs) become oPRPS if they can be validated.(ISO2204/7.4.4). Life gets simpler, maaaybe. On this basis I change my opinion above to oPRP and wait for comments. :sofa_bricks:
(I also realised that there are other situations where labelling can be a CCP, eg non-pasteurised fruit juices, specific expiry date situations.)

Kind Regards,




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Posted 20 May 2007 - 03:09 AM


If you compare 7.5 to 7.6.1 you will see that OpPRP’s does not have critical limits and has almost the same requirements of HACCP plan (CCP’s).

OpPRP’s are control measures that you have to evaluate or observe (not measurements are involved) during monitoring.

This is from ISO/TS-22004

""The development of the operational PRP(s) may follow the design of the HACCP plan (see 7.6.1 of ISO 22000:2005)""

You just eliminate the “critical limit” column from a traditional HACCP plan form.

Using examples from your plant.

If you have a juice pasteurizer, you have a critical limit (temperature) –

For strainers (in physical hazards) you don’t. -- Strainers have a particular mesh; but you do not measure size mesh when monitoring, you observe or evaluate.



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Posted 21 May 2007 - 03:53 PM

:biggrin: Thank you Charles and Erasmo for your fast and comprehensive answers!!!

I have to think everything through and may come back on the topic again.

Thanks again!
Agleh :biggrin:


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Posted 22 May 2007 - 08:38 AM

:biggrin: Thank you Charles and Erasmo for your fast and comprehensive answers!!!

I have to think everything through and may come back on the topic again.

Thanks again!
Agleh :biggrin:

Nothing to add except welcome to the forums Agleh. :welcome:


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