PREREQUISITE PROGRAMMES (PRPs) To HACCP

• Basic Conditions to ensure food safety

• Umbrella term covering various practices –
GAP Good Agricultural Practices
GMP Good Manufacturing Practices
GHP Good Hygiene Practices
GSP Good Storage Practices
GDP Good Distribution Practices
GTP Good Transportation Practices
GCP Good Consumer Practices
Etc

IICT/HABC_L3/Dec 2021/PRPs 1
 Why prerequisite programmes?
• Most hazards are introduced due to poor hygienic practices
• Many hazards can be controlled by good hygiene practices
• The purpose of HACCP is to allow businesses to focus
control at critical points
• Without well functioning prerequisite programmes we risk
either :
– Identifying so many critical points that we cannot focus our
efforts and resources
– Not taking sufficient account of hazards that should have
been controlled by our GHPs

IICT/HABC_L3/Dec 2021/PRPs 2
PRPs – the Foundation of HACCP

Focus on:
raw materials, product
and processes
HACCP
Focus on:
Production environment,
facility, programs and people
PRPs

IICT/HABC_L3/Dec 2021/PRPs 3
 Pre-Requisite Programmes
(Umbrella term which covers GAP, GMP, GHP and
other Good Practices)
• Covered in Codex General Principles of Food Hygiene
(CAC/RCP-1) and other Codex Hygiene Codes for various food
sectors (Milk : RCP 57, Tree nuts : RCP 6, etc)
• Covered in EC Regulations 852/2004
• Covered in USFDA (cGMP in CFR 21 Part 117)
• Covered in Food Safety and Standards Regulations (India)
Schedule IV of FSS (Registration & Licensing) Regulations,
2011
• And other similar documents
IICT/HABC_L3/Dec 2021/PRPs 4
 Sanitation
Current Good
Standard
Manufacturing
Operating
Practices
HACCP
Procedures

cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS

CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE SANITATION

WAREHOUSING TRACEABILITY
SUPPLIER
AND AND PEST CONTROL
CONTROL
DISTRIBUTION RECALL

IICT/HABC_L3/Dec 2021/PRPs 5
 HACCP
cGMP SSOP

FACILITIES

IICT/HABC_L3/Dec 2021/PRPs 6
Facilities
Broadly covers :
(Dealt in detail in later slides)

 Building
 Sanitary facilities
 Lighting
 Floors, walls, ceilings, doors
 Ventilation
 Water supply
 Waste disposal system

IICT/HABC_L3/Dec 2021/PRPs 7
 Facilities

Things to consider:
- design
- materials
- construction
Includes programs for the
- layout following:
 cleaning and sanitation
 maintenance and repair
 pest control

IICT/HABC_L3/Dec 2021/PRPs 8
 Facilities - Buildings
Must be designed & constructed to ensure:
 hygienic food handling
 effective cleaning & sanitation
 prevention of entry of pests
 safety of personnel

• Location, construction, With the following areas:

maintenance according to - rest & dining areas
sanitary design principles - locker rooms
• cleaned on a regular basis - landscape garden/trees
• Lay-out follows a straight- - comfort rooms
line process flow - medical clinic

IICT/HABC_L3/Dec 2021/PRPs 9
 Facilities - Buildings

Areas of a Plant:
• Receiving area
• Ingredient storage area
• Processing area
• Finished product
warehousing area
• Toilet area

Plant Lay-out

IICT/HABC_L3/Dec 2021/PRPs 10
 Facilities - An example of Factory Layout
Main entrance

A simple
factory layout Laboratory Administration
with all
departments
housed within a
single
compound
Production Area EA

Raw
Raw Material Storage FPS
materials

EA = Employee amenities
Final
FPS = Finished Products Storage products
IICT/HABC_L3/Dec 2021/PRPs 11
 Facilities - An example of Factory Layout
Raw
materials
Alternative
arrangements
of Raw Material Storage
departments
under a single Main
compound entrance
A
Production Area
A = Administration
L = Laboratory L
Finished Product Storage
EA = Employee EA
amenities
Final
products
IICT/HABC_L3/Dec 2021/PRPs 12
 Facilities - Sanitary Facilities

• Supplied with running water

• Handwashing sink near
processing area & comfort
rooms
• Taps of non-hand operable type
• Sinks provided with soap, nail
brush & clean towels
• Facilities for washing &
disinfecting equipment

IICT/HABC_L3/Dec 2021/PRPs 13
Facilities - Lighting

• Source: fluorescent light with no glare &

shadow
• Provided with a cover (not of glass)
• Adequate and appropriate to location
• Required in food preparation area,
warehousing area, handwashing stations,
restrooms

IICT/HABC_L3/Dec 2021/PRPs 14
Facilities - Floors

• Concrete, kept clean regularly, free of

debris, & properly drained (slope)
• Durable & water resistant
• No cracks, depression, or low areas
• Drains & gutters carefully planned &
located

IICT/HABC_L3/Dec 2021/PRPs 15
Facilities - Walls & Ceilings
• Impervious to moisture, easily
cleanable, smooth & light colored
• Walls can be tiles, cement blocks, bricks,
concretes & metals
• Roof is simple, watertight, sufficiently
high, & adequately vented
• Coving between walls, walls & floors &
walls & ceilings should be sealed

IICT/HABC_L3/Dec 2021/PRPs 16
Facilities - Doors

• Wide
• Open outward
• Made of corrosion-resistant or
suitable metal with adequate impact
strength
• Self-closing
• With air screen/air curtain or plastic
curtain/strip curtain

IICT/HABC_L3/Dec 2021/PRPs 17
 Facilities - Buildings Ventilation

• Remove obnoxious odors, heat, &

moisture from the plant
• Introduce fresh air, free of any
foreign odors & product
contaminants
• Provide a comfortable environment
for the employees
• Exhaust fan made of rustproof -
coated steel

IICT/HABC_L3/Dec 2021/PRPs 18
Facilities - Water Supply

• Sufficient for operations from

adequate source
• Safe & sanitary quality (meeting
national standards)
• Suitable temperature
• Under pressure as needed
• Supplied by a reputable source

IICT/HABC_L3/Dec 2021/PRPs 19
 Facilities - Waste Disposal System

• Must meet regulatory requirements

• Must not cause pollution problems or
create breeding places for pests
• Sewage system is connected to the
public sewerage system or ETP
• Drains adequate to volume of waste
water generated

IICT/HABC_L3/Dec 2021/PRPs 20
 HACCP
cGMP SSOP

FACILITIES PREMISES

IICT/HABC_L3/Dec 2021/PRPs 21
Premises
• area where the plant is located
and its surroundings

Includes programs for the

following: • maintained such that food is
kept from adulteration and
 cleaning and sanitation
contamination
 maintenance and repair
• should also consider security
 pest control
and safety
• location & size must support &
facilitate maintenance &
sanitary operations

IICT/HABC_L3/Dec 2021/PRPs 22
 Premises
Other considerations…
- no domestic animals - free from objectionable
- free from garbage/ waste odors, smokes, dust &
other contaminants
- free from pollution and dirt
- no flooding - no weeds or grass
- concrete roads & parking
space

IICT/HABC_L3/Dec 2021/PRPs 23
 HACCP
cGMP SSOP
PRODUCTION
FACILITIES PREMISES
EQUIPMENT

IICT/HABC_L3/Dec 2021/PRPs 24
 Production Equipment

• The primary objective is to prevent

adulteration and contamination of
raw materials and food products with
lubricants, fuel, fragments or any
other foreign matter from equipment

IICT/HABC_L3/Dec 2021/PRPs 25
 Production Equipment
 constructed & installed in compliance with sanitary
principles
 Made of stainless steel/plastic and food-grade
 Made of impervious corrosion-resistant, easily
cleanable, resistant to chipping, & durable material
 Smooth seams on food-contact surfaces

 installed & kept in manner that supports

 preventive maintenance;
 replacement of malfunctioning parts;
 calibration; and
 cleaning schedules

IICT/HABC_L3/Dec 2021/PRPs 26
 Production Equipment
Example of Bad Tank Design Example of Good Tank Design
Products cannot be fully drained Products can be fully drained

IICT/HABC_L3/Dec 2021/PRPs 27
 HACCP
cGMP SSOP
INGREDIENTS
PRODUCTION
FACILITIES PREMISES AND
EQUIPMENT RAW MATERIALS

IICT/HABC_L3/Dec 2021/PRPs 28
Ingredients & Raw Materials

 Should be received, stored, handled & transported

under specific sanitary & environmental conditions
 Have Certificate of Analysis (COA) or Letter of
Guarantee (LOG) from suppliers
May be based on international standards &
publications based on scientific research
Should include sampling procedures, analytical
methodology & limits for acceptance

IICT/HABC_L3/Dec 2021/PRPs 29
Ingredients & Raw Materials
 Inspected as soon as it is issued from the stockroom
 Do sensory & chemical analysis
 Temperature of receipt in some cases (Fish,Meat,Milk,etc)
 Canned raw material should be analyzed according to quantity,
expiry date, and presence of dents, bulges, punctures, and leakage
 Fresh raw material should be analyzed based on weight, presence
of soil particles, bruises, discoloration
 Results of inspection should be recorded in a Raw Material
Inspection Form
 Return non-conforming raw materials to supplier

IICT/HABC_L3/Dec 2021/PRPs 30
Ingredients & Raw Materials

 Store properly;
separately
 Follow FIFO/FEFO
 When in doubt, throw it
out!
 Never put raw food
over prepared food.

IICT/HABC_L3/Dec 2021/PRPs 31
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
MATERIALS

PERSONAL HYGIENE

IICT/HABC_L3/Dec 2021/PRPs 32
 Personal Hygiene

 proof of good health (medical and dental certificates)

 health questionnaire & reporting agreement
 regular training of personnel
 procedures on handling personnel with illness
 Exclusion policy
 first aid kit accessible

IICT/HABC_L3/Dec 2021/PRPs 33
 Personal Hygiene - General Guidelines
A. Protective Clothing
 Suitable, company issued protective clothing shall be worn in food
production or storage areas

B. Laundry
 Protective clothing should be laundered regularly & effectively
 Adequate changes of protective should be available
 Storage facility for clean protective clothing
 Clean & soiled protective clothing should
have separate storage bins

C. Staff Change Facilities

 Personal lockers should be available
 Clean or soiled protective clothing should not be stored in lockers
 Periodic checking for compliance of locker should be done

IICT/HABC_L3/Dec 2021/PRPs 34
 Personal Hygiene - General Guidelines
D. Protective Hair Covering
 Disposable (if possible)
 Worn by all in production or storage areas
 Beards should also be covered

E. Personal Hygiene
 Wash hands prior to entering food production or storage areas and
in between food handling and after use of toilet
 Fingernails should be kept short, clean & unvarnished
 Gloves should be suitable, disposable, changed frequently & their
disposal controlled to avoid product contamination
 Cuts & grazes should be covered with waterproof plasters
 Avoid unhygienic practices – smoking, spitting, scratching face with
hand

IICT/HABC_L3/Dec 2021/PRPs 35
 Personal Hygiene - General Guidelines
F. Jewelry
 Observe company rules on jewelry while in food production areas

G. Eating, Smoking & Drinking

 Strictly restricted to designated areas
 Must be followed by proper hand-washing

H. Health Screening
 All staff who will be entering food production, storage & packing
areas should complete a Company Health Questionnaire

IICT/HABC_L3/Dec 2021/PRPs 36
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CHEMICAL PERSONAL
CONTROL HYGIENE

IICT/HABC_L3/Dec 2021/PRPs 37
 Chemical Control

• Follow appropriate
segregation, labeling, use
& storage procedures of
food & non-food
chemicals

• Store under secure

conditions

IICT/HABC_L3/Dec 2021/PRPs 38
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE SANITATION

IICT/HABC_L3/Dec 2021/PRPs 39
 Cleaning and Sanitation
 Cleaning is removing the dirt you can see on a surface. Sanitizing is
reducing the unseen germs on a surface to a safe level.
 Clean and Sanitize all things that come in contact with food,
including equipments, surfaces and also which can be a source of
hazards – premises, buildings, utilities, etc
 Effective management of sanitation programs includes
education, participation & proper delegation of
responsibilities among employees
 Written detailed plans, procedures, schedules &
checklists regarding cleaning & sanitizing of food &
non-food processing equipment & facilities; Records
 Evaluation of existing cleaning procedures
 Detailed program of control for storage & use of cleaning & sanitizing
chemicals

IICT/HABC_L3/Dec 2021/PRPs 40
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
WAREHOUSING
AND
DISTRIBUTION

IICT/HABC_L3/Dec 2021/PRPs 41
Warehousing and Distribution
Lot Identification
• Lot – a definitive quantity of a commodity produced under
essentially the same conditions
• Each container should be embossed or permanently marked in
code or in clear to identify producing factory and lot
• Permanent, legible and dated records and pertinent processing
details should be kept for a period exceeding the shelf-life of
the product but not exceeding two years
• Records regarding initial distribution of the lot should be kept

IICT/HABC_L3/Dec 2021/PRPs 42
 Warehousing and Distribution
Storage Principles
• First-in-First-Out (FIFO) System should be implemented
• Create a system, such as dating goods on receipt and placing new
deliveries behind those already in storage to guarantee that FIFO
is followed
• Keep potentially hazardous foods out of the temperature danger
zone (40˚F - 140˚F or 4.4˚C - 60˚C).
• Store food products and raw materials separately only in
designated areas for storage in order to eliminate
the risk of contamination

IICT/HABC_L3/Dec 2021/PRPs 43
Warehousing and Distribution
• Keep all goods in clean, undamaged wrappers or packages
• Elimination/ minimizing contamination of goods during
storage
• Periodic inspection of product during storage
• Keep storage areas clean and dry
• this rule applies to dry storage, refrigerators, freezers,
and heated cabinets
• Keep vehicles for transporting food clean

IICT/HABC_L3/Dec 2021/PRPs 44
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
WAREHOUSING TRACEABILITY
AND AND
DISTRIBUTION RECALL

IICT/HABC_L3/Dec 2021/PRPs 45
 Traceability and Recall
• System which implements proper coding or labeling of raw
materials and finished products in the anticipation of
circumstances which will require complete traces of product
retrievals
• All raw materials and products should be lot-coded and recall
system in place so that rapid and complete traces and recalls can
be done

IICT/HABC_L3/Dec 2021/PRPs 46
Traceability and Recall

RECALL
• It is a firm’s voluntary removal of product from trade or
consumer channels (e.g. importers or manufacturers) to
protect the public from consuming adulterated or
misbranded products
• any corrective action by a company needed to protect
consumers from potentially adverse effects of a
contaminated, adulterated, or misbranded product
• Does not include a market withdrawal or stock recovery

IICT/HABC_L3/Dec 2021/PRPs 47
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
WAREHOUSING TRACEABILITY
SUPPLIER
AND AND
CONTROL
DISTRIBUTION RECALL

IICT/HABC_L3/Dec 2021/PRPs 48
Supplier Control
Types of Supplier Control used by firms:
1. Receipt of raw materials only from known sources of supply
2. HACCP Plan required for classification as ‘certified suppliers’
3. Inspection of ingredients and shipping containers for evidence of
unsanitary conditions
4. In-house lab analysis and random sampling
5. Quick tests of indicator parameters used to assess acceptability
of raw materials
6. Screening of new vendors -initial sample analysis by outside
laboratory and random sampling for 6 months
7. Vendor audits performed by third parties.
8. Documentation of problems with supplier’s products

IICT/HABC_L3/Dec 2021/PRPs 49
 HACCP
cGMP SSOP
INGREDIENTS
FACILITIES PREMISES EQUIPMENT AND
RAW MATERIALS
CLEANLINESS
CHEMICAL PERSONAL
AND
CONTROL HYGIENE
SANITATION
WAREHOUSING TRACEABILITY
SUPPLIER
AND AND PEST CONTROL
CONTROL
DISTRIBUTION RECALL

IICT/HABC_L3/Dec 2021/PRPs •cont

50
 Pest Control
 Three steps for pest control
 Restrict entry
 Physical control
 Chemical control
 Effective measures that prevent the entry & proliferation
of pests from receiving, processing, packaging & storage
areas
 Establishments & surrounding areas regularly examined
for infestation
 Continuous application through effective sanitation & use
of chemicals

IICT/HABC_L3/Dec 2021/PRPs 51
Pest Control
 Examples of Pest Control Program
 Double-screened windows & doors
 Self-closing door
 Elimination of cracks in floors & walls
 Double-screened gutter drains
 Placing garbage cans outside the plant & far
from the processing area
 Covered food storage
 Cleaning spills immediately
 Food storage 6 inches above the floor & from the wall
 Use of hanging flypapers & glue traps
 With the aid of a pest control company
IICT/HABC_L3/Dec 2021/PRPs 52
 MANAGING PREREQUISITE PROGRAMS
 Documentation
 Written guidelines & procedures
 Records of previously encountered problems
& solutions that were implemented

 Training
 Periodic
 Well-designed
 Will cater to all level of employees

 Verification Activities
 Routines performed by supervisors that guarantee the
implementation of prerequisite programs, corrective
actions & that programs are functioning as intended
IICT/HABC_L3/Dec 2021/PRPs 53
PREREQUISITE PROGRAM ASSESSMENT

 Check existence & effectiveness during design

& implementation of HACCP plan
 Document & regularly audit progress
 Aspect that may be incorporated into HACCP
plan

IICT/HABC_L3/Dec 2021/PRPs 54
 Summary
• Prerequisite programmes are the basic conditions for the production of
safe food. In fact, it is the foundation on which HACCP System is developed
or established.
• Prerequisite programmes should include:
 Hygienic design of food handling, storage facilities and equipment
 Operational control standards for handling all ingredients and
materials
 Maintenance, cleaning & disinfection schedule
 Pest control
 Waste management
 Personal hygiene standards, equipment/clothing for personnel
 Hygienic transport standards, as appropriate
 Product information and labelling
 Training programmes
• Ensure that prerequisite programmes “will work effectively” through
validation

IICT/HABC_L3/Dec 2021/PRPs 55