Introduction:


The Foundation for Food Safety Certification 22000 (FSSC 22000) is a company-level certification that helps organizations ensure the supply of safe food and beverages.

The scheme uses international and independent standards such as ISO 22000, ISO 9001, ISO/TS 22003, and technical specifications for sector-specific Pre-Requisite Programs (PRPs), such as ISO/TS 22002-1.

This Process Street checklist is designed to help you successfully implement all of the measures necessary to satisfy this particular PRP program, which is essential for gaining FSSC 22000 certification if you are in the food processing industry.

The checklist will cover the following areas:

  • Construction & layout of buildings
  • Premises workspace
  • Utilities (air, water, energy)
  • Waste disposal
  • Equipment, cleaning & maintenance
  • Purchased materials
  • Prevention of cross-contamination
  • Cleaning & sanitizing
  • Pest control
  • Personnel hygiene
  • Rework
  • Product recall procedures
  • Warehousing

It should be noted that ISO 22000 identifies areas and programs that must be considered during the development of PRPs (listed above). However, the standard leaves the responsibility for developing the details of the program to the organization; it does not give specific requirements for the pest control program, it asks you as the organization to determine what is appropriate for your organization.

Bearing in mind that not every requirement is clearly stated, it is essential for your team to be incredibly diligent during the internal audit process to put your company in the best position possible for gaining certification when a licensed third-party certifying body conducts the external audit and scheduled audits thereafter.

A little info about Process Street

Process Street is superpowered checklists. By using our software to document your processes, you are instantly creating an actionable workflow in which tasks can be assigned to team members, automated, and monitored in real-time to ensure they are being executed as intended, each and every time.

The point is to minimize human error, increase accountability, and provide employees with all of the tools and information necessary to complete their tasks as effectively as possible.

Enter basic details

First things first, enter basic details including the company name, location, and inspection date. 


Construction & layout of buildings:

Check environment is suitable

The first thing to inspect is the work environment. 

Check locations of establishments are suitable

Check to verify that the location(s) of your establishments are in compliance with FSSC 22000 requirements. 

Summarize construction & layout of buildings

Use the form field below to summarize the construction and layout of your buildings.

You can also upload and/or link to documents that contain relevant information (e.g. floor plans).

Approval: Construction & layout of buildings

Will be submitted for approval:
  • Check environment is suitable
    Will be submitted
  • Check locations of establishments are suitable
    Will be submitted
  • Summarize construction & layout of buildings
    Will be submitted

Layout of premises workspace:

Check internal design and layout

Check the internal design and layout of your workspace.

Check internal structures and fittings

Check to ensure that the internal structure and fittings of your building(s) are clean and in good condition. 

Check location of equipment

Check that your food processing equipment is appropriately located for compliance with FSSC 22000 requirements.

Inspect laboratory facilities

Inspect laboratory facilities to make sure they meet the requirements for FSSC 22000 certification.

Inspect temporary/mobile premises

Inspect any temporary/mobile premises in your workspace to make sure their condition meets FSSC 22000 certification requirements. 

Check food storage and packaging materials

Check your food storage and packaging materials to make sure they meet the requirements for FSSC 22000 certification. 

Summarize layout of premises workspace

Use the form field below to summarize the layout of your workspace.

You can also upload and/or link to documents that contain relevant information (e.g. internal design photographs, details regarding packaging materials).

Approval: Layout of premises workspace

Will be submitted for approval:
  • Check internal design and layout
    Will be submitted
  • Check internal structures and fittings
    Will be submitted
  • Check location of equipment
    Will be submitted
  • Inspect laboratory facilities
    Will be submitted
  • Inspect temporary/mobile premises
    Will be submitted
  • Check food storage and packaging materials
    Will be submitted
  • Summarize layout of premises workspace
    Will be submitted

Utilities (air, water, energy):

Check water supply

To begin evaluating your utilities for FSSC 22000 certification, first check your water supply.

Check boiler chemicals

Check that the boiler chemicals you are using are in compliance with FSSC 22000 requirements.

Check air quality and ventilation

Check that the air quality and ventilation system throughout your work premises meet the requirements for FSSC 22000 certification.

Check compressed air and other gases

Check that any kind of compressed air or other gases present in your facilities is stored and handled in a way that meets the requirements for FSSC 22000 certification

Check lighting

As a final step in the evaluation of utilities, check lighting systems throughout the premises to make sure they meet FSSC 22000 requirements. 

Summarize utilities

Use the form field below to summarize utilities throughout your workspace.

You can also upload and/or link to documents that contain relevant information (e.g. layout of ventilation systems)

Approval: Utilities

Will be submitted for approval:
  • Check water supply
    Will be submitted
  • Check boiler chemicals
    Will be submitted
  • Check air quality and ventilation
    Will be submitted
  • Check compressed air and other gases
    Will be submitted
  • Check lighting
    Will be submitted
  • Summarize utilities
    Will be submitted

Waste disposal:

Check containers for waste and hazardous substances

Ensure that all containers used for the disposing of waste and hazardous substances are handled appropriately, as required for FSSC 22000 certification.

Check waste management and removal

Check to verify that your waste management and removal system is compliant with FSSC 22000 requirements. 

Inspect drains and drainage

Ensure that your drainage system is in good enough condition that it meets the FSSC 22000 requirements

Summarize waste disposal systems

Use the form field below to summarize your waste disposal system.

You can also upload and/or link to documents that contain relevant information.

Approval: Waste disposal

Will be submitted for approval:
  • Check containers for waste and hazardous substances
    Will be submitted
  • Check waste management and removal
    Will be submitted
  • Inspect drains and drainage
    Will be submitted
  • Summarize waste disposal systems
    Will be submitted

Equipment, cleaning & maintenance:

Inspect product contact surfaces

Inspect product contact surfaces to make sure they are compliant with FSSC 2000 requirements. 

Check temperature control and monitoring equipment

Ensure that temperature control and monitoring equipment meets the requirements for FSSC

Check cleaning plant, utensils and equipment

Ensure that your cleaning plans, all utensils and equipment are in good condition and meet FSSC 22000 requirements.

Check preventive and corrective maintenance

Check your preventive and corrective maintenance measures to make sure they are in compliance with FSSC 22000 requirements

Summarize equipment suitability, cleaning and maintenance

Use the form field below to summarize your equipment suitability, cleaning and maintenance.

You can also upload and/or link to documents that contain relevant information.

Approval: Equipment, cleaning & maintenance

Will be submitted for approval:
  • Inspect product contact surfaces
    Will be submitted
  • Check temperature control and monitoring equipment
    Will be submitted
  • Check cleaning plant, utensils and equipment
    Will be submitted
  • Check preventive and corrective maintenance
    Will be submitted
  • Summarize equipment suitability, cleaning and maintenance
    Will be submitted

Management of purchased materials:

Evaluate selection and management of suppliers

Evaluate how you go about selecting and managing your suppliers to make sure that you are meeting the requirements for FSSC 22000 certification. 

Evaluate handling of incoming materials

Evaluate how you handle incoming materials. 

Summarize management of purchased materials

Use the form field below to summarize how you manage purchased materials.

You can also upload and/or link to documents that contain relevant information.

Approval: Management of purchased materials

Will be submitted for approval:
  • Evaluate selection and management of suppliers
    Will be submitted
  • Evaluate handling of incoming materials
    Will be submitted
  • Summarize management of purchased materials
    Will be submitted

Prevention of cross contamination:

Evaluate microbiological cross contamination management

Evaluate your process for managing microbiological cross-contamination that may take place during food processing. 

The best way to prevent the spread of viruses to food is to ensure that hands are washed and that they are clean and protected when handling food. Anytime a human hand touches something, there is a risk of contamination with harmful microorganisms or chemicals.

Evaluate allergen management

Evaluate your allergen management process to ensure it meets the requirements for FSSC 22000 certification

Allergen (as defined by FSSC): A substance (usually a protein) capable of causing a response (allergic reaction) mediated by the immune system (GFSI BRv7:2017).

Summarize measures for preventing cross contamination

Use the form field below to summarize what measures you take to prevent cross contamination.

You can also upload and/or link to documents that contain relevant information.

Approval: Prevention of cross-contamination

Will be submitted for approval:
  • Evaluate microbiological cross contamination management
    Will be submitted
  • Evaluate allergen management
    Will be submitted
  • Summarize measures for preventing cross contamination
    Will be submitted

Cleaning & sanitizing:

Check cleaning and sanitizing agents and tools

Inspect all cleaning and sanitizing agents and tools to ensure they are in compliance with FSSC 22000 regulations. 

Evaluate cleaning in place (CIP) systems

Evaluate your CIP systems to ensure they are compliant with FSSC 22000 requirements.

Underperforming cleaning routines are a known root cause of food safety incidents and when an estimated 75% of cleanings executed on a daily base in the food industry are not properly validated and poorly documented (EHEDG, 2016), many contaminated products could be entering the marketplace. - Diversey

In addition to frequent verification such as visual checks or swab tests, cleaning in place (CIP) systems and protocols should be routinely validated to operate with confidence in cleaning processes and demonstrate legal compliance.

Evaluate monitoring of sanitation effectiveness

Inspect and evaluate what measures are in place to monitor sanitation effectiveness. 

Summarize cleaning and sanitizing

Use the form field below to summarize what measures you take to ensure proper cleaning and sanitization.

You can also upload and/or link to documents that contain relevant information.

Approval: Cleaning & sanitizing

Will be submitted for approval:
  • Check cleaning and sanitizing agents and tools
    Will be submitted
  • Evaluate cleaning in place (CIP) systems
    Will be submitted
  • Evaluate monitoring of sanitation effectiveness
    Will be submitted
  • Summarize cleaning and sanitizing
    Will be submitted

Pest control:

Evaluate pest control program

Evaluate your pest control program to ensure it meets the requirements for FSSC 22000 certification. 

This means that a formal, define program must be documented and implemented. 

Such programs should also guarantee that: 

  • Contracted pest control services or organizations have appropriately trained staff
  • Procedures are applied so as to prevent potential contamination of products
  • Results of inspections are analyzed to identify trends

In FSSC 22000, the importance of establishing hygiene, cleaning, and incoming materials inspection procedures to avoid creating an environment conducive to pest activity is emphasized.

Check access prevention systems

FSSC 22000 mentions that potential pest access points shall be sealed and openings must be designed to minimize entry of pests. 

Check all of the acess points in your facility and ensure that access prevention systems have been put in place.

Check for harbourage and infestations

It is obviously incredibly important to not have any harbourage or infestations within your food processing facility.

Conduct a thorough inspection of the work premises to make sure there are no infestations.

Evaluate monitoring and detection systems

Evaluate the monitoring and detection systems you have in place for pest control and ensure they meet the standards required for FSSC 22000 certification.

Summarize pest control

Use the form field below to summarize what measures you take for pest control.

You can also upload and/or link to documents that contain relevant information.

Approval: Pest control

Will be submitted for approval:
  • Evaluate pest control program
    Will be submitted
  • Check access prevention systems
    Will be submitted
  • Check for harbourage and infestations
    Will be submitted
  • Evaluate monitoring and detection systems
    Will be submitted
  • Summarize pest control
    Will be submitted

Personnel hygiene & employee facilities:

Check hygiene facilities and toilets

Ensure that hygiene facilities and toilets are kept clean and in good working order. 

There should always be full soap dispensers present and a documented schedule for cleaning. 

Inspect staff canteens and eating areas

Inspect all staff canteens and eating areas to ensure they meet the requirements for FSSC 22000 certification. 

Evaluate personal hygiene and protective clothing

Its critical to make sure that all staff working inside the food processing facility are donning the appropriate workwear and protective clothing. 

In general, maintaining good personal hygiene is essential. 

Here are 9 important tips for establishing a good personal hygiene policy:

  1. Thoroughly wash and dry your hands before handling food, and wash and dry them again frequently during work.
  2. Dry your hands with clean towels, disposable paper towels, or under an air dryer.
  3. Never smoke, chew gum, spit, change a baby’s nappy or eat in a food handling or food storage area.
  4. Never cough or sneeze over food or where food is prepared or stored.
  5. Wear clean protective clothing, such as an apron.
  6. Keep your spare clothes and other personal items away from where food is stored and prepared.
  7. If you have long hair, tie it back or cover it.
  8. Keep your nails short so they are easy to clean and don’t wear nail polish as it can chip into the food.
  9. Avoid wearing jewelry, or only wear plain banded rings and sleeper earrings.

Summarize personnel hygiene and employee facilities

Use the form field below to summarize what measures you take to maintain personal hygiene and employee facilities.

You can also upload and/or link to documents that contain relevant information.

Approval: Personnel hygiene & facilities

Will be submitted for approval:
  • Evaluate microbiological cross contamination management
    Will be submitted
  • Evaluate allergen management
    Will be submitted
  • Summarize measures for preventing cross contamination
    Will be submitted

Rework:

Evaluate storage, identification and traceability

Evaluate storage, defect identification, and traceability methods to ensure they meet the standards of FSSC 22000. 

When handling rework in your facility, note the following:

  1. Apply tags with product identification information, which may include the name of the product, lot code, and date of production. You can also use color-coded containers to identify rework material.   
  2. Store rework in a way that prevents contamination with potential food hazards and growth of micro-organisms
  3. Store rework in an appropriate environment that prevents or minimizes food spoilage. For example, meat rework must be stored in a temperature-controlled environment at four degrees Celsius or less to prevent or limit the growth of microorganisms.

Follow general good storage practices. For example:  

  • Store rework materials off the floor and away from walls to minimize contamination
  • Cover and protect rework materials
  • Use clean containers
  • Ensure storage room is adequate for storing food products (ex: avoid pest access, permit maintenance and cleaning)  

Evaluate rework usage

Proper rework usage is incredibly important for maintaining a clean work environment in which the risk of contamination is low. 

Examples of reworking may include:

  • Re-forming meat patties rejected for being broken, underweight or improperly breaded  
  • Reprocessing dough leftover from the previous production  
  • Repacking cookies that were mislabeled  
  • Re-cleaning grains that did not meet specifications  
  • Reprocessing cooked sausage as pizza topping or sausage crumble
  • Re-baking bread crumbs that will be used to coat other food products, such as breaded foods  
  • Incorporating sausage end trimmings from one batch into the production of a new batch  
  • Mixing production from one day into a batch from a different day
What is the risk of mishandling rework?

Mishandling rework material may result in potential hazards such as:

  • Presence of undeclared allergens due to cross-contamination —  for example when a product containing a specific allergen is mixed with a product that does not contain the ingredient and labelling is not changed to acknowledge the fact.
  • Contamination with pathogenic bacteria due to improper personal hygiene or product handling practices
  • Growth of pathogenic bacteria due to temperature abuse
  • Presence of undeclared restricted ingredients in the final product — for example, addition of cured meat to a fresh meat product, which should not contain curing agents

Summarize rework

Use the form field below to summarize what measures you take to properly manage rework.

You can also upload and/or link to documents that contain relevant information.

Approval: Rework

Will be submitted for approval:
  • Evaluate storage, identification and traceability
    Will be submitted
  • Evaluate rework usage
    Will be submitted
  • Summarize rework
    Will be submitted

Product recall procedures:

Evaluate product recall procedure

Evaluate your product recall procedure to ensure it meets the requirements outlined in FSSC 22000 documents. 

Below is a pdf that contains useful information on how to conduct the procedure in a timely and professional manner, although it is not written specifically for those seeking FSSC 22000 certification. 

If you have any reason to suspect that food could pose a hazard to consumers,
you must recall it. This is regardless of how the concern comes to your attention.

Summarize product recall procedures

Use the form field below to summarize your product recall procedures.

You can also upload and/or link to documents that contain relevant information.

Approval: Product recall procedures

Will be submitted for approval:
  • Evaluate product recall procedure
    Will be submitted
  • Summarize product recall procedures
    Will be submitted

Warehousing:

Inspect vehicles, conveyances and containers

Inspect and make sure that all vehicles and containers meet the requirements laid out by FSSC 22000. 

Below is the official FSSC 22000 brochure for information on Transport & Storage certification.

Summarize warehousing practices

Use the form field below to summarize your warehousing.

You can also upload and/or link to documents that contain relevant information.

Approval: Warehousing

Will be submitted for approval:
  • Inspect vehicles, conveyances and containers
    Will be submitted
  • Summarize warehousing practices
    Will be submitted

Final steps:

Make overall comment on internal audit

Presented below is a summary of each area you have evaluated over the course of this checklist. 

Now is the time to review the audit, verify the information, and make an overall comment on how it went and where the organization stands in terms of achieving FSSC 22000 certification.

Also, take the time to identify and document action items moving forward. 


Construction & layout of buildings:

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Premises workspace:

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Utilities (air, water, energy):

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Waste disposal:

{{form.Summary_of_your_waste_disposal_system}}

Equipment, cleaning & maintenance:

{{form.Summary_of_equipment_suitability,_cleaning_and_maintenance}}

Purchased materials:

{{form.Summary_of_management_of_purchased_materials}}

Prevention of cross-contamination:

{{form.Summary_of_measures_to_prevent_cross_contamination}}

Cleaning & sanitizing:

{{form.Summary_of_cleaning_and_sanitization}}

Pest control:

{{form.Summary_of_measures_taken_for_pest_control}}

Personnel hygiene:

{{form.Summary_of_measures_taken_for_personal_hygiene_and_employee_facilities}}

Rework:

{{form.Summary_of_rework_management}}

Product recall procedures:

{{form.Summary_of_product_recall_procedures}}

Warehousing:

{{form.Summary_of_warehousing_practices}}

Approval: Internal audit successfully completed

Will be submitted for approval:
  • Make overall comment on internal audit
    Will be submitted

Sources:

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