Prerequisite of HACCP – What Are Prerequisite Programs?
As we all know that for every food manufacturing industry food safety certification is something extremely important and to have food safety systems certification, HACCP is the core requirements. For every HACCP there are some steps which needs to be ensured to produce safe and legal food products.
We have listed down HACCP pre-requisites programs which needs to be ensured and implemented. This is a general list which can be used in every food manufacturing facility after tweaking a little as per their nature of food and process.
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| Sr# | Pre-requisite Program | Documents | Compliance Method for Audit |
| 1 | Exterior of facility is maintained adequately clean and proofed. | Physical verification | Annual food safety audit Report+ Pest Control Report + Monthly food safety inspection |
| 2 | Building structure, roof, walls and foundation are maintained to prevent leakages | Physical verification | Annual food safety audit Report+ Pest Control Report + Monthly food safety inspection |
| 3 | Licenses and permits are in place from the local authority for the production and distribution of food products | List of licenses and permits | Annual audit by regulatory authority for the license |
| 4 | Equipment for manufacturing food is food compatible/grade | Manufacturing manual | Site internal food safety audit report |
| 5 | Hand Wash stations are are installed, operational and soap and sanitizer is available. | Physical verification | Site internal food safety audit report |
| 6 | Drains are designed in way that there is a slope and no stagnant water issue. Drains are maintained in good, condition. | Physical verification | Site internal food safety audit report |
| 7 | Sufficient equipment is in place to ensure adequate temperatures and humidity levels are achieved. | Storage Monitoring SOP | Daily temperature and humidity checks. |
| 8 | Raw materials purchased from approved suppliers & delivered in suitable conditions | Supplier approval program & SOP | Vehicle inspection on arrival checklist, Certificate of analysis check, incoming material testing results |
| 9 | Raw materials are segregated from finished products and are segregated as per their allergenic content. | Warehousing SOP | Site internal food safety audit report |
| 10 | Flow throughout manufacturing process is from RM to finished product. | HACCP flow diagram + Plant layout | Site internal food safety audit report |
| 11 | Manufacturing process separated into sections to avoid cross contamination of non allergenic ingredients with allergenic ingredients. | Plant layout and product flow | HACCP validation, site monthly food safety audit report |
| 12 | FIFO is in place. | Warehousing SOP | Site internal food safety audit report |
| 13 | Water Supply is as per regulatory requirements | Water Quality | Water testing reports |
| 14 | Cleaning utensils are available for specific types of cleaning and are easily identifiable. | Cleaning SOP | Site internal food safety audit report |
| 15 | Cleaning schedule in place for all equipment and locations. | Cleaning Schedule | Cleaning records, inspection records |
| 16 | CIP,COP in place | Cleaning Schedule | Cleaning records, inspection records |
| 17 | Waste Segregation is in place along with measures to prevent cross contamination and pest infestation | Cleaning SOP, waste management SOP | Site internal food safety audit report |
| 18 | Preventive Maintenance Program including frequencies of maintenance. | Maintenance program | Maintenance Records |
| 19 | Process and Lab Equipment calibration. | Control of monitoring and measuring devices procedure | Calibration records ( In house and 3rd party calibration records) |
| 20 | Good Personal Hygiene Practices | Personal Hygiene Procedure | Hygiene inspection record + Medical testing reports |
| 21 | Lighting is adequate and light bulbs are covered. | Glass & hard plastic procedure | Annual glass & hard plastic audit |
| 22 | Chemical Control | MSDS, Approved chemical list | Food grade certificates, MSDS,TDS |
| 23 | Controlled Access to Processing Areas | Access policy | Access records |
| 24 | Raw Materials storage | Warehousing procedure | Storage records for Temperature and Humidity |
| 25 | Product and raw material Traceability | Traceability policy | Traceability exercises records |
| 26 | Pest Control Program | integrated Pest management procedure | Pest monitoring records, fumigation records, inspection records |
