In BRC issue 6, the major change in ‘Food Safety Plan –HACCP’ is addition of prerequisite program. The prerequisite program must be well documented with control measure and monitoring procedure. Also should be covered during annual review of HACCP plan.
The prerequisite program should be prepared as following:
- Premises
- Personal
- Products
Premises – Premises, Glass & Hard Plastic Control, Water Quality, Pest Control, Cleaning & Sanitising Schedule, Preventive maintenance – Equipment & Building, Calibration, Positive Air Control (High care area), transport/logistics
Personal: Personal hygiene, Staff training, Hand washing, Protective clothing, Medical screening, Staff return to work after illness or holidays, Visitors & contractors
Products: Supplier Selection, Finished product specification, Packaging materials, Traceability, Temperature control, Allergen controls.
An example:
| PROCESS STEP | HAZARDS | CONTROL MEASURES | CRITICAL LIMITS | MONITORING PROCEDURES & RESPONSIBILITIES | CORRECTIVE ACTION |
| Premises | Physical Hazards:
Physical contamination by foreign bodies from fabrication |
|
No foreign bodies | Internal Audits | Areas repaired as required |
| Glass & Hard plastic Control | Physical Hazards:
Product contaminated by glass/plastic |
|
Effective ( intact) guards & covers in place | Fort nightly glass & hard plastic audit by QA supervisors | Refer to glass breakage procedure -GFF024PR. |
| Water Quality | Biological Hazards:
Introduction of micro-organisms from contaminated (poor quality) water |
|
As per PHLS guidelines
Coliforms 0/250mL ACC @ 22°C/72h :100/mL ACC@ 37°C/48h : 20/mL |
Yearly sampling send for micro analysis | Investigate the cause & analysis the risk. Resample & retest. If require contact supplier |
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