HACCP Prerequisites – What Are Prerequisite Programs?
In the food manufacturing, food safety certification is essential to ensure the production of safe and compliant products. At the heart of any food safety certification lies HACCP (Hazard Analysis and Critical Control Points), a fundamental requirement. To implement HACCP effectively, it’s crucial to establish and maintain prerequisite programs that form the foundation for producing safe and legal food products.
We have compiled a list of HACCP prerequisite programs that must be established and implemented to support an effective food safety system. This general list serves as a foundation and can be customized to suit the specific nature of food products and manufacturing processes at any facility.
List of HACCP Prerequisites
| Sr# | HACCP 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 |
Conclusion
HACCP prerequisites are building blocks of an effective food safety management system, laying the groundwork for identifying and controlling potential hazards. By implementing these foundational programs, food manufacturing facilities ensure not only compliance with regulatory standards but also the production of safe and high-quality food products. Customizing and continuously improving these prerequisites to align with the unique nature of each operation is vital for maintaining food safety, building consumer trust, and achieving long-term success in the industry.
