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PAS 220
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MODULE
PAS 220 : 2008
PREREQUISITE PROGRAMMES
ON FOOD SAFETY
FOR FOOD MANUFACTURING
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Module Objectives
By the end of this module , you will be able to :
a) Explain the purpose of PAS 220 and the benefits to an organization of using the
Specification.
b) Outline key definitions and terminology used in PAS 220.
c) Outline the key requirements of PAS 220.
Contents :
Session
Title
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SESSION 1
INTRODUCTION TO PAS 220
Objectives :
When you have completed this topic , you will be able to :
- Explain the background to PAS 220 .
- Under the reasons for the development of PAS 220 .
- Be aware of the compatibility between BS EN ISO 22000 and PAS 220.
- Understand the benefits of PAS 220.
Key Points :
- The background and development of PAS 220 .
- The benefits of implementing PAS 220 .
- ISO 22000 and PAS 220.
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SESSION 1
INTRODUCTION OF PAS 220
1 Introduction :
BSI (British Standards Institution) has published PAS 220 : 2008 Prerequisite programmes
of food safety for food manufacturing. This Publicly Available Specification (PAS) sets out
the requirements for the prerequisite programmes that are required by BS EN ISO 22000
and which assist in controlling food safety hazards; these include items such as the layout of
premises and workspace, personnel hygiene and product recall procedures.
PAS 220 is largely based upon the requirements of Codex Alimentarius , but has in
addition, been cross-referenced with existing industry practices. Sponsored by Danone,
Kraft, Nestle and Unilever through the Confederation of the Food and Drink Industries of
the European Union (CIAA), the development of PAS 220 was overseen by a Steering
Group with included representatives from the Food and Drink Federation (FDF), the French
National Association of Food Industries (representing CIAA), General Mills Europe
(representing the FDF Food Hygiene Committee), Lioyd's Register Quality Assurance,
McDonald's and ProCert.
PAS 220 is designed for use by any organization, regardless of size or complexity, involved
in the manufacturing stage of the food chain. It is intended that PAS 220 will be used in
conjunction with BS EN ISO 22000 Food Safety Management Systems. The requirements
are intended to assist any organization in the food chain which needs to establish
prerequisite programmes to assist in controlling food safety hazards. The intent is that PAS
220 is recommended to ISO as a formal international standard complimenting ISO 22000.
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SESSION 2
PAS 220: OVERVIEW AND CLAUSES 4 TO 18
Objectives :
When you have completed this topic , you will be able to:
- Understand the intent of PAS 220 .
- Understand the structure of PAS 220.
- Be aware of the scope of PAS 220.
- Identify the terms and definitions used in the Standard.
- Understand the requirements for PRP's based on PAS 220.
Key Points :
- The purpose of BS EN 16001.
- The structure of BS EN 16001.
- BS EN 16001, clauses 3.1 to 3.3.
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SESSION 2
BS EN 16001 OVERVIEW
1 Introduction :
BS EN ISO 22000 sets out specific food safety requirements for organizations in the food
chain. One such requirement is that organizations establish, implement and maintain
prerequisite programmes (PRP) to assist in controlling food safety hazards (ISO 22000 :
2005, clause 7). This PAS is intended to support management systems designed to meet the
requirements specified in ISO 22000 and set out detailed requirements for those
programmes.
PAS 220 does not duplicates the requirements given in ISO 22000 and is intended to be
used in conjunction with ISO 22000 and not as a stand along specification.
2 The structure of PAS 220:
PAS 220 comprises 18 clauses and a number of sub-clauses, and a bibliography:
1 Scope
2 Normative references
3 Terms and definitions
4 Construction and layout of buildings
4.1 general requirements
4.2 Environment
4.3 Locations and establishments.
5 Layout of premises and workspace
5.1 General requirements
5.2 Internal design, layout sand traffic patterns
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3 Scope
PAS 220 specifies requirements for establishing, implementing and maintaining prerequisite
programmes (PRP) to / enable organization in the food chain to better control food safety
hazards.
The Specification is application to all organizations , whatever their size or complexity ,
which are involved in the manufacturing stage of the food chain and with to implement PRP
in such a way as to address the requirements of ISO 22000 : 2005 , clause 7.
PAS 220 is not designed nor intended to be applied to other areas of the food supply chain,
only manufactures.
The Specification recognizes that food manufacturing operations are divers and as such not
all of the requirements specified will apply to each establishment or process.
Exclusions
Where exclusions are made or alternative measures implemented, these need to be justified
by a hazard assessment. Any exclusions or alternative measures that are used should not
affect the ability of the organization to comply with the requirement set out in PAS 220.
Examples of such exclusions might include the additional aspects relating to:
- Rework
- Product recall procedures
- Warehousing
- Product information and consumer awareness
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A separate, secure storage area must be provided for cleaning materials , chemicals and
other hazardous substances.
Bulk or agricultural crop materials can be excluded from this requirement but justification
must be documented in the organization's food safety management system.
6 Utilities - Air , Water , Energy
The provision to , and distribution routes for utilities to and around processing and storage
areas shall be designed to minimize the risk of product contamination. Utilities quality shall
be monitored to minimize product contamination risk.
6.2 Water Supply
The Specification demands that there must be an adequate supply of potable water, with
appropriate facilities for storage, distribution and where needed, temperature control of the
water, Potable water must conform to WHO guidelines for drinking water.
Water used as a product ingredient [including as ice or steam], or in contact with products
or product surfaces must meet specified quality and microbiological requirements relevant
to the product.
Water for applications where there is a risk for indirect product contact [e.g. jacketed
vessels, heat exchangers] must meet specified quality and microbiological requirements
relevant to the application.
Non portable water shall have a separate supply system that is labeled, not connected to the
potable water system and is prevented from reflux into the potable system.
Where water supplies are chlorinated, checks shall assure that the residual chlorine level at
point of use remains within defined limits.
The specification recommends that water pipes must be capable of being disinfected.
6.3 Boiler chemicals
Boiler chemicals, if used, must be either:
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The Specification recommends the of oil free compressors is preferred However if oil is
used it must be food grade.
Requirements for filtration, humidity [RH%] and microbiology shall be specified. Filtration
of the air should be as close to the point of use as is practicable.
6.6 Lighting
Adequate lighting [natural or artificial] shall be provided to allow personnel to operate in a
hygienic manner.
The Specification notes that the intensity of the lighting should be appropriate to the nature
of the operation.
Light fixtures shall be protected sufficient to assure that materials, product or equipment are
not contaminated in the case of breakages.
7 Waste Disposal
Systems shall be in place to assure that waste materials are identified, collected, removed
and disposed of in a manner which prevents contamination of products areas.
7.2 Containers for waste and inedible or hazardous substances :
Containers for waste and inedible or hazardous substances must be :
a) clearly identified for their intended purpose.
b) located in a designated area.
c) constructed of suitable, impervious material which can be readily cleaned and
sanitized.
d) closed when not in immediate use.
e) locked where the waste may pose a risk to the product.
7.3 Waste management and removal
Suitable provision must be made for the segregation, storage and removal of waste.
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The Specification requires that waste must no be allowed to accumulate in food handling or
storage areas. Removal frequencies shall be managed to avoid accumulations, with
minimum daily removal.
Labeled materials or products which are designated as waste must be disfigured or
destroyed to ensure that trademarks cannot be re'used.
The removal and destruction must be carried out by approved secure disposal contractors
and records provided.
7.4 Drains and drainage
Drains shall be designed, constructed and located so that the risk of contamination of
materials or products is avoided. Drains shall not pass over processing lines.
Drainage direction must not flow from a contaminated area to a clean area.
8 Equipment suitability, cleaning and maintenance
Food contact equipment shall be designed and constructed to facilitate appropriate cleaning
, disinfection and maintenance. Contact surfaces shall not affect, or be affected by the
intended product or cleaning system.
8.2 Hygienic design
Here , the requirement is that equipment must meet established principles of hygienic
design, including :
a) smooth, accessible, cleanable surfaces, self draining in wet process areas;
b) use of materials compatible with intended products and cleaning or flushing agents;
c) framework not penetrated by holes or nuts and bolts
Piping and ductwork must be cleanable, drainable, and with no dead ends.
Equipment shall be designed to minimize contact between the operator's hands and the
products.
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Local area PRP requirements shall apply to maintenance areas and maintenance activities in
process areas. Maintenance personnel shall be trained in the product hazards associated with
their activities.
9 Management of purchased materials
Purchasing of materials which impact food safety must be controlled to assure that the
suppliers used have the capability to meet the specified requirements. The conformance of
incoming materials to specified requirements shall be verified.
9.2 Selection and management of suppliers
There must be a defined process for the selection , approval and monitoring of suppliers,
including:
a) assessment of the supplier's ability to meet quality and safety expectations,
requirements and specifications.
b) a description of how suppliers are assessed;
c) monitoring the performance of the supplier to assure continued approval status.
The Specification notes that suppliers may be assessed by:
a) audit of the supplying site prior to accepting materials for production;
b) appropriate third party certification.
The process used to select and monitor suppliers must be justified by risk assessment,
including the potential risk to the final product.
9.2 Incoming material requirements - raw/ingredients/packaging
Delivery vehicles shall be checked prior to & during unloading to verify that the quality and
safety of the material has been maintained during transit. For example, seals are intact, free
from infestation, temperature records exist and so on.
Materials must be inspected, tested or certified to verify conformance to specified
requirements prior to acceptance or use. The method of verification must be documented.
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The Specification notes that the frequency and scope should be based on the hazard
presented by the material and the risk assessment which has been carried out be the supplier.
Materials which do not conform to specifications shall be handled under a defined
procedure, which assure they are prevented from unintended use.
Access points to bulk material receiving lines must be identified, capped and locked.
Discharge into such systems must take place only after approval and verification of the
material to be received.
10 Measures for the prevention of cross contamination
Programs shall be in place to prevent, control and detect contamination. Measure to prevent
physical, allergenic and microbiological contamination shall be included.
10.2 Microbiological cross contamination
Areas where the potential for micro cross contamination exists [airborne or from traffic
patterns] shall be identified and an appropriate. A segregation or zoning plan must be
implemented.
A hazard assessment must be carried out to determine potential contamination sources,
susceptibility of the product, an appropriate control measures for these areas;
a) separation of raw from finished or ready to eat [RTE] products;
b) structural segregation - physical barriers / walls / separate buildings;
c) access controls with requirements to change into appropriate required workwear;
d) traffic patterns or equipment segregation - people, materials, equipment & tools
[including use of dedicated tools];
e) air pressure differentials.
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Clothing mandated for food protection or hygiene purposes shall not be used for any other
purpose.
Work wear must
- not have buttons;
- outside pockets above waist level;
- be laundered at appropriate intervals, to a defined standard suitable for the intended use
of the garments;
- provide adequate coverage to assure that hair, perspiration etc. cannot contaminate the
product.
Hair, beards and moustaches shall be protected [i.e. completely enclosed] by restraints
unless risk analysis indicates otherwise.
Any gloves that area used for product contact must be clean and in good condition. The
Specification notes that the use of Latex gloves should be avoided where possible.
Shoes for use in processing areas must be fully enclosed, and made from non absorbent
materials.
Personal protective equipment, where required, shall be designed to prevent product
contamination and maintained in hygienic condition.
13.5 Health status
Employees shall undergo a medical examination prior to employement in food contact
operations [including site catering], unless documented risk assessment indicates otherwise.
Additional medicals shall be carried out at intervals defined by the organization, subject to
legal restrictions in the country of operation.
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INDEX
Module Objectives.............................................................................................................................. 2
Contents : ............................................................................................................................................ 2
SESSION 1 INTRODUCTION TO PAS 220 ................................................................................. 3
Objectives : ......................................................................................................................................... 3
Key Points : ......................................................................................................................................... 3
1 Introduction :................................................................................................................................... 4
The benefits of PAS 220: ................................................................................................................... 5
PAS 220 : ............................................................................................................................................. 5
ISO 22000 and PAS 2200 ................................................................................................................... 5
SESSION 2 PAS 220: OVERVIEW AND CLAUSES 4 TO 18 .................................................... 6
Objectives : ......................................................................................................................................... 6
Key Points : ......................................................................................................................................... 6
1 Introduction :................................................................................................................................... 7
2 The structure of PAS 220: .............................................................................................................. 7
3 Scope............................................................................................................................................... 11
Exclusions ......................................................................................................................................... 11
4 Terms and Definitions .................................................................................................................. 12
5 Clauses 4 to 18 ............................................................................................................................... 12
4 Construction and layout of buildings .......................................................................................... 12
4.2 Environment ............................................................................................................................... 12
4.3 Locations of establishments....................................................................................................... 12
5 Layout of premises & workspace ................................................................................................ 13
5.2 Internal design, layout and traffic patterns ............................................................................. 13
5.3 Internal structures and fittings ................................................................................................. 13
5.4 Location of equipment ............................................................................................................... 14
5.5 Laboratory facilities ................................................................................................................... 14
5.6 Temporary / mobile premises & vending machines ............................................................... 14
5.7 Storage of food, ingredient and non food chemicals ............................................................... 14
6 Utilities - Air , Water , Energy ..................................................................................................... 15
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