Operational Prerequisite Programme

Training Guide

Operational Prerequisite Programmes

Operational prerequisite programmes are put in

place for significant hazards that are not controlled in the HACCP plan at Critical

Control Points.

Prerequisite Programmes

All PRP’s should approved by the Food Safety Team, their relevance and the reason for their inclusion should be documented in the Hazard analysis including details of why the PRP is appropriate to the organisation and the control of food safety hazards.

PRP’s are categorised into two types:

1. Prerequisite Programmes

2. Operational Prerequisite Programmes

Identifying Operational Prerequisite Programmes

Use our unique HACCP Calculator ISO 22000 to help identify your Operational PRPs:

Use the simple steps to assessing Hazard significance generating a rating of 1 – 9

The calculator automatically highlights significant hazards which require critical control point assessment

Significant Hazards that are not included in your HACCP plan should be controlled by Operational Prerequisite programmes

Refer to the HACCP Training Guide - FSSC 22000 Module 2014, ISO 22000 HACCP Calculator Instructions and the HACCP Calculator to assist in your assessment.

Identifying Operational Prerequisite Programmes

We will now go through the steps to identifying Operational

Prerequisite Programmes.

Refer to the HACCP Training Guide - FSSC 22000 Module 2014, ISO 22000 HACCP Calculator Instructions and the HACCP Calculator to assist in your assessment.

For each Food Safety Hazard Identified, the acceptable level of the hazard in the end product is determined, justified and recorded taking into account regulatory requirements, customer food safety requirements, historic information, scientific literature, professional experience and intended use by the customer. This hazard list is referred to as a preliminary hazard list and covers all hazards that could potentially occur in the product.

ISO 22000 Implementation Preliminary Hazard List

Hazard Assessment

For each hazard decide what control measures are in place for the hazard.

The food safety team assess the food safety hazards using the HACCP calculator:

Firstly the Food Safety Team assess the likelihood of the hazard occurring and enter: 1 for Highly Unlikely 2 for Possible 3 for Likely Then the Food Safety Team assesses the severity of the hazard and enters: 1 for Not Severe 2 for Could possibly cause illness 3 for Severe (Could be fatal)

ISO 22000 Implementation Hazard Assessment

Pro

bab

ility

Severity

Significan

ce Step Number

Step Name Hazards Identified

1 Delivery of Ingredient A Bone 1 3 3

1 Delivery of Ingredient A Campylobacter spp. 2 3 6

1 Delivery of Ingredient A Contamination with Bacteria from pests 3 3 9

1 Delivery of Ingredient A Pesticides 3 1 3

1 Delivery of Ingredient A Salmonella spp. (S. typhimurium, S. enteriditis) 3 3 9

1 Delivery of Ingredient A Bacteria (spore-forming) General 2 2 4

1 Delivery of Ingredient A Pest control chemicals 1 1 1

ISO 22000 Implementation HACCP Calculator

Significant Food Safety Hazards Score 9 in the HACCP Calculator

The ISO 22000 HACCP Calculator can be used to help select and categorize control measures:

ISO 22000 Implementation Classification of Control Measures

ISO 22000 Selection and Categorization of Control Measures

c) Assess its place within the system relative to other control measures:

What is the place within the system relative to

other control measures? Select from drop down

list: At the end of the process

Near the end of the process

Mid process Start of process

ISO 22000 Selection and Categorization of Control Measures

So now you will have assessed the control measures as per ISO 22000 Clause 7.4.4. Based on this assessment of control measures there are 3 results: 1. Proceed to Decision Tree 2. Review Control Measure and if to use Decision Tree 3. Stop at this point not a CCP. Implement as an OPRP or consider

alternative control measures.

The calculator will automatically tell you if the step is a critical control by highlighting the box red. If will also highlight in amber any item you will need to follow up on such as a requirement to modify the step.

Determine the Critical Control Points (CCPs)

Control Measures to be Implemented as Operational Prerequisite Programmes in Green

ISO 22000 Implementation Classification of Control Measures

Validation of CCP’s and Operational Prerequisite Programmes

ISO 22000 HACCP - CCP Example

Let’s look at an example where we have identified a CCP row 11 Step 24 Pasteurization

ISO 22000 HACCP - OPRP Example

Step 28 is Storage in a Yoghurt Tank. This tank has a site glass. There is a risk of contamination from the glass if it is cracked or broken. The control measures are checking the site glass at start up and following a breakage procedure if the glass is cracked or broken.

ISO 22000 HACCP - OPRP Example

We stop at this stage and implement the control measure as an Operational Prerequisite Programme. The alternative would be to remove the hazard – remove the site glass.