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What Are the Prerequisite Programs (PRPs) Required in FSSC 22000

By May 6, 2025No Comments

What Are the Prerequisite Programs (PRPs) Required in FSSC 22000?

To build a strong foundation for food safety, FSSC 22000 certification requires not only a solid HACCP plan but also comprehensive Prerequisite Programs (PRPs). These are essential conditions and activities that create a hygienic production environment. Without effective PRPs, your critical control points may fail—putting food safety at risk. Here’s what you need to know.

What Are PRPs in FSSC 22000?

  • Preventative practices that control general hazards in the facility

  • Support the implementation of HACCP and food safety management systems

  • Address contamination risks from environment, people, equipment, and operations

  • Required based on ISO/TS 22002 series depending on sector (e.g., food manufacturing, packaging, animal feed)

  • Must be documented, implemented, maintained, and verified

Key PRPs for Food Manufacturing (ISO/TS 22002-1)

1. Construction and Layout of Buildings

  • Designed to prevent contamination

  • Proper zoning (low-risk vs. high-risk areas)

  • Smooth, cleanable walls, floors, and ceilings

2. Layout of Premises and Workspace

  • Logical product flow to reduce cross-contamination

  • Segregation of raw and finished goods

  • Adequate space for equipment and personnel movement

3. Utilities (Water, Air, Energy)

  • Safe water supply for cleaning, processing, and as an ingredient

  • Air quality control in sensitive areas

  • Maintenance and protection of utility lines

4. Waste Disposal

  • Separate collection for food, non-food, and hazardous waste

  • Covered bins and frequent disposal

  • Prevention of pest attraction and contamination

5. Equipment Suitability, Cleaning, and Maintenance

  • Made of food-grade, corrosion-resistant materials

  • Easy to clean and maintain

  • Cleaning schedules and records maintained

6. Management of Purchased Materials

  • Approved supplier list

  • Inspection and testing of raw materials

  • COAs and traceability records required

7. Measures for Prevention of Cross-Contamination

  • Color-coded tools for different zones

  • Allergen control measures in place

  • Hygiene barriers and air pressure differentials

8. Cleaning and Sanitizing

  • Written cleaning procedures for all areas and equipment

  • Verified effectiveness using swabs or inspections

  • Use of approved chemicals

9. Pest Control

  • Regular inspections and treatment by qualified personnel

  • Use of bait stations and monitoring devices

  • No pest entry points (e.g., sealed windows, doors)

10. Personnel Hygiene and Facilities

  • Handwashing stations with soap, sanitizer, and signage

  • Adequate locker rooms and toilets

  • Personal hygiene policy and enforcement

11. Rework Procedures

  • Clear identification and segregation of rework

  • Evaluation for safety and quality before reprocessing

  • Proper documentation and traceability

12. Product Recall and Withdrawal

  • Written recall procedure with roles and responsibilities

  • Mock recall testing

  • Traceability from raw materials to distribution

13. Storage and Transport

  • Temperature-controlled areas where necessary

  • Clean, secure, and pest-free storage

  • Vehicle hygiene and inspection prior to loading

14. Allergen Management

  • Identification and segregation of allergenic ingredients

  • Label checks and verification

  • Cleaning validation to prevent cross-contact

Verification and Maintenance of PRPs

  • Internal audits and inspections

  • Daily checks and documentation

  • Corrective actions for non-conformities

  • Staff training and supervision

Why PRPs Matter in FSSC 22000 Certification

  • Form the base layer of your food safety system

  • Reduce risk before reaching CCP level

  • Required for audit readiness and GFSI recognition

  • Demonstrate proactive risk management to buyers and regulators

Need Help Developing and Implementing PRPs?
At CAYS Scientific, we help food companies meet FSSC 22000 standards through:
✅ Customized PRP implementation for your industry sector
✅ Staff training on hygiene, cleaning, pest control, and more
✅ Gap assessment and audit preparation support
✅ Integration of PRPs with HACCP and ISO 22000 systems

📞 Contact CAYS Scientific today to strengthen your food safety system from the ground up—with fully compliant and effective PRPs.

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