ISO/TS 22002-1 Prerequisite Programmes on Food Safety

Technical Specification ISO/TS 22002-1 Prerequisite programmes on food safety — Part 1: Food manufacturing was first published in 2009. This technical specification effectively replaced Publically Available Specification (PAS) 220 Prerequisite programmes on food safety for food manufacturing which was published by BSI in 2008. Technical Specification ISO/TS 22002 is used in association with ISO 22000:2005 Food safety management systems - Requirements for any organization in the food chain by food manufacturers wishing to achieve FSSC 22000 certification. ISO/TS 22002-1 specifies the expected standard of prerequisite programmes which food manufacturers should implement in order to comply with ISO 22000 Clause 7 which requires prerequisite programmes to be established in order to assist in controlling food safety hazards.

  • Construction and layout of buildings and utilities
  • Layout of premises and workspace
  • Utilities
  • Supporting services including waste disposal
  • Suitability of equipment
  • Management of purchased materials
  • Measures for the prevention of cross-contamination
  • Cleaning and sanitizing
  • Pest control
  • Personnel hygiene

ISO/TS 22002 has the following sections which specify detailed requirements required of prerequisite programmes in food manufacturing:

  • 4 Construction and layout of buildings
  • 5 Layout of premises and workspace
  • 6 Utilities – air, water, energy
  • 7 Waste disposal
  • 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 procedures
  • 16 Warehousing
  • 17 Product information/consumer awareness
  • 18 Food defence, biovigilance and bioterrorism

In sections 14 to 18 ISO/TS 22002-1 specifies prerequisite programmes for food manufacturing operations that are not considered in ISO 22000 including rework, product recall procedures, warehousing product information, consumer awareness, food defence, biovigilance and bioterrorism.

ISO 22002-1 section 4 covers the construction and layout of buildings in 3 subsections; general requirements, environment and location of establishments ISO 22002-1 requires buildings to be designed, constructed and maintained such that the prevent food safety hazards and do not present a risk of contaminating the product. Potential contamination from the environment should be considered and any risks controlled. The site should be maintained with defined boundaries and adequate drainage.

ISO 22002-1 section 5 covers layout of premises and workspace in 7 subsections; general requirements, internal design, layout and traffic patterns, internal structures and fittings, location of equipment, laboratory facilities, temporary or mobile premises and vending machines, and storage. ISO 22002-1 specifies internal layouts should facilitate good manufacturing practices which provide protection against potential sources of contamination. There should be a logical flow of materials, products and personnel and segregation of raw and finished products. Walls and floors should resistant and capable of being cleaned. Ceilings and overheads shall be designed to prevent contamination. Openings should be screened. Equipment should be designed to facilitate good hygiene practices. Laboratory facilities should be sited and controlled to prevent product contamination. Microbiology laboratories should be away from manufacturing areas. Temporary structures should not encourage pests or pose a risk of product contamination. Storage facilities should allow segregation and provide protection from dust, condensation, drains, waste and minimize the risk of product contamination.

ISO 22002-1 section 6 covers utilities including air, water and energy in 6 subsections; general requirements, water supply, boiler chemicals, air quality and ventilation, compressed air and other gases, and lighting. The supply and distribution of utilities should minimize the risk of product contamination. Supplies should be monitored to ensure they are of adequate quality. An adequate supply of potable water should be available to ensure hygienic operation and adequate cleaning. Contamination of the supply with non-potable water should be prevented. Boiler chemicals should be approved and controlled. Air quality and ventilation should be controlled to prevent product contamination. As necessary air quality should be monitored. Compressed air and other gas systems should be constructed and maintained so that the gas filtered to remove dust, oil and water and is of adequate quality and to prevent product contamination. Lighting should be sufficient to facilitate hygienic operations and protected to prevent product contamination.

ISO 22002-1 section 7 covers waste disposal in 4 subsections; general requirements, containers for waste and inedible or hazardous substances, waste management and removal, and drains/drainage. Waste control systems should in place to ensure that waste is identified, handled, segregated, stored and disposed of in a manner which prevents contamination of products or production areas.

ISO 22002-1 section 8 covers equipment suitability, cleaning and maintenance in 6 subsections; general requirements, hygienic design, product contact surfaces, temperature control and monitoring equipment, cleaning plant, utensils and equipment, and preventative and corrective maintenance. ISO 22002-1 specifies the requirements for food contact equipment including the need for a hygienic design and construction which ensure that the equipment can be adequately cleaned and maintained. Food contact surfaces should be of compatible materials that are not affected by cleaning chemicals or the product. Thermal processes equipment should be designed to and meet the required process parameters in addition adequate monitoring equipment should be installed. All plant, utensils and equipment should be subject to a documented cleaning programme. Corrective and preventive maintenance programmes should be in place, particularly for equipment monitoring and/or controlling food safety hazards.

ISO 22002-1 section 9 covers the management of purchased materials in 3 subsections; general requirements, selection and management of suppliers and incoming material requirements. The purchase of materials which impact food safety must be managed to ensure that materials meet an appropriate specification. Supplier should be subject to approval and monitoring based on risk. Incoming materials should be checked to verify conformity prior to acceptance or use.

ISO 22002-1 section 10 covers measures for prevention of cross-contamination in 4 subsections; general requirements, microbiological cross-contamination, allergen management and incoming material requirements and physical contamination Measures to prevent physical, allergen and microbiological contamination should be in place. Areas with the potential for microbiological cross-contamination should be controlled and adequate segregation applied as determined by the risk. Allergens should be controlled and managed to prevent the cross-contamination of non-allergen products with allergens. Allergens when present in the product should be declared. Measures such as the control of glass and brittle materials, filtration and/or metal detection should be in place to prevent physical contamination.

ISO 22002-1 section 11 covers cleaning and sanitizing in 5 subsections; general requirements, cleaning and sanitizing agents and tools, cleaning and sanitizing programmes, cleaning in place (CIP) systems and monitoring sanitation effectiveness. Effective cleaning and sanitizing programmes should be implemented, validated and monitored to ensure that equipment and environment are maintained in a hygienic condition. Cleaning and sanitizing agents should be clearly identified and segregated. Tools and equipment should be fit for purpose and not present a food safety hazard.

ISO 22002-1 section 12 covers pest control in 6 subsections; general requirements, pest control programmes, preventing access, harbourage and infestations, monitoring/detection and eradication. Measures such as cleaning, inspection of incoming goods and monitoring should ensure the appropriate hygienic conditions are in place to discourage pests. A pest prevention programme which is managed by a responsible should be in place to control access, prevent habourage, prevent infestation and detect and eradicate any pests.

ISO 22002-1 section 13 covers personnel hygiene and employee facilities in 8 subsections; general requirements, personnel hygiene facilities and toilets, staff canteens and designated eating areas, work wear and protective clothing, health status, illness and injuries, personal cleanliness and personal behavior. The personal behavior, cleanliness and hygiene of all personnel including visitors and contractors should be managed reduce the risks posed to manufacturing areas and products. Personnel hygiene facilities and toilets should be available with appropriate changing and hand washing facilities. There should be designated areas for food storage and consumption. Work wear should be managed, hygienic and provide adequate protection to the product. Procedures should be in place to manage the health status, illness and injuries of all personnel including visitors and contractors.

ISO 22002-1 section 14 covers rework in 3 subsections; general requirements, storage, identification and traceability and rework usage. Procedures should be in place to ensure product safety, quality, traceability and regulatory compliance are not compromised by rework operations.

ISO 22002-1 section 15 covers product recall in 2 subsections; general requirements and product recall requirements. Product recall procedures, including a list of key contacts, should be in place to ensure that products failing to meet requirements can be identified, located and removed from the supply chain.

ISO 22002-1 section 16 covers warehousing in 3 subsections; general requirements, warehousing requirements and vehicles, conveyances, and containers. Materials and products should be stored in clean, dry, ventilated areas, subject to stock rotation and protected from sources of contamination. Specified warehousing environmental conditions such as temperature should be monitored and controlled. Vehicles, conveyances, and containers should be hygienic and provide protection to materials and products.

ISO 22002-1 section 17 covers product information and consumer awareness. Information such as allergen content, storage, preparation and serving instructions should be passed to consumers; this can be by means of label information.

ISO 22002-1 section 18 covers food defence, biovigilance, and bioterrorism in 2 sections, general requirements and access controls. Hazard to products posed by potential acts of sabotage, vandalism or terrorism should be assessed and controlled by appropriate preventative measures including access control.

Food manufacturers wishing to achieve FSSC 22000 are required to meet all of the requirements of Technical Specification ISO/TS 22002-1 unless exclusion can be justified by hazard risk assessment.

Technical Specification ISO/TS 22002-1 Refers to the following standards:

  • CODEX CAC/RCP 1:2003, Recommended international code of practice — General principles of food hygiene
  • ISO 14159:2002, Safety of machinery — Hygiene requirements for the design of machinery
  • ISO/TS 22003, Food safety management systems — Requirements for bodies providing audit and certification of food safety management systems
  • ISO/TS 22004:2005, Food safety management systems — Guidance on the application of ISO 22000:2005
  • BS PAS 220:2008, Prerequisite programmes on food safety for food manufacturing

By Tony Connor - Managing Partner. (Google+)

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