PAS 220:2008 PREREQUISITE PROGRAMMES ON

FOOD SAFETY FOR FOOD MANUFACTURING

A publicly available specification prepared by the

British Standards Institution (BSI) to specify the

requirements for prerequisite programmes to

assist in controlling food safety hazards.

PAS 220

INTENTION:

To be used in conjunction with BS EN ISO

22000 to support management systems

to meet requirements with regard to

prerequisite programmes.

PAS 220

PAS 220

ISO 22000BRC

SANS 10330HACCP

PREREQUISITE PROGRAMS

ISO 22000BRC

SANS 10330HACCP

PREREQUISITE PROGRAMS

PAS 220 is applicable to ALL organizations, regardless

of size and complexity, which are involved in a

step of the food chain.

Food manufacturing operations are diverse in nature

therefore not all the requirements in the PAS 220

may apply to an individual organization.

PAS 220

Why are prerequisite programmes

necessary?

PAS 220

Prerequisite programmes are the basic conditions and

activities that are necessary to maintain a

hygienic environment throughout the food chain

suitable for the production, handling and

distribution of safe food products.

PAS 220

PRPs assist in controlling the likelihood of

introducing food safety hazards such as

biological, chemical or physical in the

product or processing environment.

PAS 220

MACHINERY

NOTE

PRPs need to be appropriate to the product

and processes of the organization.

PAS 220

Prerequisite programmes can cover a wide

range of activities.

PAS 220 specifies requirements related to the

following:

PAS 220

CONSTRUCTION AND LAYOUT OF BUILDINGS

• Appropriate design and construction of buildings • Consideration of potential sources of contamination

from the environment• Identification of boundaries and access control. • Maintenance of buildings and surrounding areas.

PAS 220

LAYOUT OF PREMISES AND WORKSPACE

• Designed to facilitate good hygiene and manufacturing

processes• Logical flow of materials, products and people• Physical separation of raw from processed areas• Protection of openings intended for transfer of

materials• Internal structures and fittings such as walls, floors,

ceilings, windows• Location of equipment• Laboratory facilities• Temporary structures• Storage facilities

PAS 220

UTILITIES – AIR, WATER, ENERGY

• Sufficient supply of potable water• Boiler chemical approved• Established requirements for filtration, humidity and

microbiological specifications for air used as an

ingredient or in direct contact with food• Compressed air• Adequate lighting to enable operation in a hygienic

manner

PAS 220

WASTE DISPOSAL

• Identification, collection and disposal of waste

materials• Appropriate containers for waste• Segregation and storage of waste• Drains and drainage

PAS 220

EQUIPMENT SUITABILITY, CLEANING AND MAINTENANCE

• Design and construction of food contact equipment• Hygienic design eg. Smooth, accessible, compatible with

intended products• Temperature control and monitoring equipment• Cleaning plant, utensils and equipment • Preventive and corrective maintenance

PAS 220

MANAGEMENT OF PURCHASED MATERIALS

• Selection and management of suppliers• Incoming material requirements• Inspection of incoming material • Nonconforming received materials• Identification, segregation and handling of purchased

materials

PAS 220

MEASURES FOR PREVENTION OF CROSS CONTAMINATION

• Microbiological cross contamination• Allergen management• Physical contamination• Chemical contamination

PAS 220

CLEANING AND SANITIZING

• Cleaning and sanitizing agents and tools• Cleaning and sanitizing programmes• Cleaning in place (CIP) systems• Monitoring sanitation effectiveness

PAS 220

PEST CONTROL

• Pest control programmes• Preventing access• Harborage and infestations• Monitoring and detection• Eradication

PAS 220

PERSONNEL HYGIENE AND EMPLOYESS FACILITIES

• Adequate numbers, locations and means of

hygienically washing and drying• Adequate number of toilets• Not directly open into production• Changing facilities for personnel• Canteens and designated areas for food storage• Work wear and protective clothing• Health status• Illness and injuries• Personal cleanliness• Personal behavior

PAS 220

REWORK

• Storage, identification and traceability • Segregation requirements for rework• Classification for rework• Rework usage – permissible incorporation

PAS 220

PRODUCT RECALL PROCEDURES

• Recall requirements• System for identification, location and removal • Need for public warning

PAS 220

WAREHOUSING

• Effective control of warehousing temperature,

humidity and environmental conditions• Proper stacking• Waste materials, lubricants, chemicals, cleaning

materials and pesticides stored separately• Vehicles, conveyances and containers

PAS 220

PRODUCT INFORMATION / CONSUMER AWARENESS

• Proper presentation• Labeling of pre-packed foods

PAS 220

FOOD DEFENCE, BIOVIGILANCE AND TERROISIM

• Assessment of hazards to products posed by potential

acts of sabotage, vandalism or terrorism• Access controls

PAS 220

PAS 220

PAS 220 – IS THIS SOMETHING NEW?

SANS 10049 - REQUIREMENTS FOR A PREREQUISITE PROGRAMME (PRP) SYSTEM

SANS 10330 – PREREQUISITE REQUIREMENTS (CLAUSE 6 )

ISO 2200 - PREREQUISITE REQUIREMENTS (CLAUSE 7.2)

ESTABLISHING REQUIREMENTS FOR PAS 220

DESIGN

• Buildings

• Internal layout

• Movement patterns

• Openings

• Walls, floors, drains, ceilings and overhead fixtures

• Equipment

• Laboratory

• Storage areas

• Distribution of utilities

PAS 220

PAS 220

DOCUMENTED POLICY

• Personal behavior

PAS 220

PROCEDURES, PROTOCOLS, PROGRAMMES

• Protocols for air quality monitoring and control• Waste management• Cleaning and sanitizing programmes• Preventative maintenance programmes• Procedures for releasing maintained equipment• Selection, approval and monitoring of suppliers• Prevention, control and detection of contamination• Defined procedures for use and breakage of glass / brittle material • Pest management• Monitoring programmes• Personnel hygiene• Product recall• Labeling procedures

PAS 220

RECORDS

• Destruction of waste• Raw material conformance• Hazard assessment• Glass breakage• Pesticide usage• Traceability records for rework

• Records are evidence of compliance to the requirements and necessary for review purposes.

PAS 220

SABS APPROACH TO AUDITING PAS 220

• Requirements are audited in audits for compliance to SANS 10330 and ISO 22000.

• Previously SANS 10049 used as guideline (currently under revision)• PRPs is one of 25 “clauses” for requirements in SANS 10330 and one of 34 in

ISO 22000. As such, the records of the audits were included in the entire audit scope and although records of these conformance inspection are maintained in the auditors trails, details were not included in the report.

• Report format will be altered to highlight conformance to PAS 220 requirements (eg as in BRC report)

• An additional certificate will be issued to existing companies who comply with the requirements of the PAS 220.

PAS 220

THE END GOAL

A LOCALLY ACCEPTED AND RECOGNIZED CERTIFICATION BY ALL PARTIES AND STAKEHOLDERS THAT WILL CONTRIBUTE TO A REDUCTION IN MULTPLE AUDITS WITH THE AIM OF PROVIDING SAFE FOOD TO CONSUMERS AT AN ECONOMICAL PRICE.

THE END

THANK YOU