Prerequisite Programs — FlaxSeedsPro Processing Facility¶

Document No.: FSP-PRP-001
Revision: 01
Effective Date: 2026-07-20
Approved By: Food Safety Team Leader

Table of Contents¶

Facilities & Building Maintenance
Water & Steam Quality
Cleaning & Sanitation
Pest Control
Waste Management
Equipment Maintenance
Personnel Hygiene
Supplier Control
Receiving & Storage
Chemical Control
Foreign Material Control
Training Program

1. Facilities & Building Maintenance¶

Objective: To maintain the facility in a condition that prevents contamination of flaxseed products from building-related sources (structural defects, condensate, dust, pests).

Scope: All production areas, packaging areas, raw material storage, finished product storage, dry ingredient handling zones, and maintenance/utility rooms.

Procedure Summary: - Floor drains: All drains in production areas are trapped, sealed, and numbered. Drains are inspected daily for standing water, odours, and debris. Cleaning is performed weekly using a foaming drain cleaner followed by hot water rinse. Drain covers are removable for cleaning and are slot-width ≤ 6 mm to prevent pest ingress. - Wall finishes: Walls are finished with smooth, washable epoxy paint or fibreglass-reinforced panels up to 2 m height. All wall-floor junctions are coved (radius ≥ 38 mm) to prevent soil accumulation. Inspected monthly for cracks, peeling, or damage. - Ceilings: Sealed plasterboard or suspended ceiling tiles with smooth, non-shedding finish. No exposed insulation in food handling zones. Inspected quarterly for water stains, mould, and pest harbourage. - Lighting: Shatter-resistant LED fixtures with diffuser covers in all production areas. Light intensity minimum 500 lux at inspection points, 200 lux in general areas. Fixtures cleaned quarterly; diffuser integrity checked monthly. - Ventilation: HVAC system with HEPA filtration (MERV-13 minimum) for production areas. Positive air pressure maintained in packaging rooms relative to adjacent zones. Temperature and humidity logged continuously. Condensate pans cleaned monthly. Air handling units inspected quarterly.

Frequency: Daily visual inspection by shift supervisor; weekly comprehensive inspection by Maintenance Lead; monthly PRP audit by QA Supervisor.

Responsibility: Maintenance Engineer (D. Osei), Production Manager (B. Martinez).

Records: Facility Inspection Checklist (FSP-FAC-001), Maintenance Work Orders (FSP-MWO-001), HVAC Log (FSP-HVAC-001).

2. Water & Steam Quality¶

Objective: To ensure that all water and steam used in the facility (cleaning, processing, sanitation) meets potable water standards and does not introduce chemical or microbiological contamination.

Scope: Municipal water supply, on-site storage tanks, hot water system, steam generator (boiler), ice machines (if present), and all water-use points in production, cleaning, and wash-down areas.

Procedure Summary: - Source: Facility uses municipal (city) potable water supply. Annual water quality report obtained from the municipality and filed in QA records. - Potable water standard: Must meet WHO Drinking Water Guidelines and local regulatory standards for potable water. Microbiological: zero coliforms and E. coli per 100 mL. Chemical: residual chlorine 0.2–1.0 mg/L at point of use. - Testing frequency: Residual chlorine tested daily at three representative points (inlet, production wash-down, cleaning station) using DPD test kits. Total coliform and E. coli tested monthly by accredited third-party lab (IDEXX Colilert or equivalent method). Full potable water panel (chemical + microbial) tested annually. - Steam quality: Steam used for cleaning equipment is generated from potable water. Boiler chemicals (anti-scalant, corrosion inhibitor) are food-grade and approved for direct-contact steam. Quarterly boiler blowdown and inspection per manufacturer schedule. - Backflow prevention: Backflow prevention devices (reduced pressure zone assemblies) installed at all cross-connection points. Tested annually by certified plumber. Records maintained in water quality log. - Hot water tempe-rature: Hot water for sanitation is maintained at ≥ 82°C at point of delivery for cleaning-in-place (CIP) applications. Recorded daily.

Frequency: As specified above (daily for chlorine, monthly for microbiology, annually for full panel).

Responsibility: Maintenance Engineer (D. Osei), QA Supervisor (C. Singh).

Records: Water Quality Log (FSP-WQL-001), Third-Party Lab Reports (FSP-LAB-001), Boiler Log (FSP-BLR-001), Backflow Prevention Test Certificate (FSP-BFP-001).

3. Cleaning & Sanitation¶

Objective: To ensure all equipment, utensils, food-contact surfaces, and production areas are cleaned and sanitized to a microbiologically acceptable level, preventing cross-contamination and allergen carryover.

Scope: All production rooms (Routes A–E), packaging areas, storage rooms, shared utensils, grinding mill, expeller press, filtration equipment, conveyor belts, metal detectors, and employee break rooms.

Procedure Summary: - Program scope: Master Sanitation Schedule (MSS) covers all areas with defined cleaning method, chemical concentration, contact time, water temperature, and responsible personnel. - Cleaning methods: - Dry cleaning (primary): Compressed air (oil-free, filtered), vacuum cleaning (HEPA-filtered vacuums), dry brushes, and lint-free wipes. Used for dry processing areas (Routes A–D). - Wet cleaning (oil area only): Hot water rinse (≥ 82°C) + food-grade alkaline foaming cleaner + potable water rinse + sanitizer (peracetic acid 80–120 ppm, 30 s contact time). Limited to Route E (oil pressing) area. - Allergen changeover: Full dry-cleaning protocol between brown and golden flaxseed runs. Visual inspection + ATP swab verification (< 30 RLU per swab area). Production sequence is light (golden) → dark (brown) to minimize cross-contact. - Chemical approvals: All cleaning chemicals approved per FSP-CHEM-002 (Approved Chemical List). Only food-grade, NSF-registered chemicals used. MSDS maintained in chemical binders. - Verification: ATP bioluminescence swabs post-cleaning (target ≤ 30 RLU for food-contact, ≤ 100 RLU for non-contact). Visual inspection by QA prior to start of production. Monthly surface contact plates for APC and Enterobacteriaceae.

Frequency: Per Master Sanitation Schedule — daily, weekly, and monthly frequencies assigned by area. Deep cleaning after allergen changeover and quarterly for all areas.

Responsibility: Sanitation Lead (F. Nakamura), QA Supervisor (C. Singh).

Records: Master Sanitation Schedule (FSP-MSS-001), Daily Cleaning Log (FSP-CLN-001), ATP Results Log (FSP-ATP-001), Chemical Usage Log (FSP-CUL-001).

4. Pest Control¶

Objective: To prevent pest entry, harbourage, and infestation within the facility through an integrated pest management (IPM) program, minimizing the risk of product contamination from insects, rodents, birds, or other pests.

Scope: Entire facility interior (production, storage, warehouse, break rooms, offices) and exterior perimeter (building envelope, grounds, waste area).

Procedure Summary: - Rodent control: Exterior rodent bait stations (tamper-resistant, lockable) placed at 15 m intervals along building perimeter. Stations containing single-feed brodifacoum blocks (waxed, weather-resistant). Interior glue boards placed along walls in dry storage at 8 m intervals. All stations/boards numbered on master map. Inspected weekly by trained in-house staff. Bait replaced when > 50% consumed or every 90 days. - Insect control: Insect Light Traps (ILTs) with UV-A lamps and glue boards installed in production areas (every 100 m²), receiving bay, storage, and break rooms. Lamps replaced annually at start of flying insect season. Glue boards replaced every 4 weeks or when > 50% covered. Weekly catch count logged. Trend analysis quarterly. - Fumigation: If threshold exceedances occur (cumulative catch > 30/trap/week for flies), contract fumigator engaged for phosphine or CO2 treatment of impacted area. Pre-fumigation and post-fumigation clearance testing performed. - Exclusion measures: All exterior doors fitted with spring-loaded door-closers, rubber sweeps (≤ 6 mm gap), and dock levelers sealed. Windows in production areas are non-opening (sealed). Vents screened with 16-mesh (1.2 mm) stainless steel. Pipe penetrations sealed with expanding foam or stainless steel wool + silicone. Bird spikes installed on roof edges and air intakes. - Pest activity logs: Daily pest sighting log maintained by all staff. Any pest sighting inside production immediately reported to QA and logged. Zero tolerance for rodents, birds, and cockroaches inside production areas. - External contractor: Licensed pest control company conducts monthly deep inspection of all bait stations, ILTs, and exclusion points. Provides formal inspection report.

Frequency: Weekly (internal), monthly (external contractor).

Responsibility: QA Supervisor (C. Singh), external pest control contractor.

Records: Pest Control Log (FSP-PST-001), ILT Catch Log (FSP-ILT-001), Bait Station Inspection Report (FSP-BSR-001), Contractor Service Report (FSP-CSR-001), Pest Sighting Report (FSP-PSR-001).

5. Waste Management¶

Objective: To manage all waste streams (solid, liquid, hazardous) in a manner that prevents pest attraction, cross-contamination, and environmental pollution.

Scope: All solid waste (production trimmings, packaging waste, rejected product), liquid waste (wash water, oil residues, cleaning solutions), and hazardous waste (used batteries from equipment, spent fluorescent tubes, chemical containers).

Procedure Summary: - Solid waste: Lidded, colour-coded bins with pedal-operated lids (green = non-organic, brown = organic/food waste). Bins emptied at end of each shift (minimum). Food waste bins located only in designated waste holding room — never inside production. Waste room cleaned and sanitized daily. Contracted waste hauler collects general waste weekly, organic waste daily (or as needed). - Liquid waste: Wash water from oil press area routed through grease trap before entering municipal sewer. Grease trap cleaned by contractor quarterly. Oil-contaminated wash water (Route E) collected in sealed drums for disposal by licensed waste oil recycler. - Hazardous waste: Chemical containers triple-rinsed and crushed before disposal. Spent fluorescent tubes, used batteries, and expired chemicals stored in segregated, labelled, sealed containers in locked chemical waste cabinet. Picked up by licensed hazardous waste contractor annually or upon request. - Containers: All waste containers are durable, easy to clean, and labelled with waste type. No open containers allowed in production or storage areas. Waste compactors are located outside, sealed, and cleaned monthly.

Frequency: Daily (emptying/cleaning), weekly (waste room deep-clean), quarterly (grease trap), annually (hazardous waste contractor).

Responsibility: Sanitation Lead (F. Nakamura), Production Manager (B. Martinez).

Records: Waste Disposal Log (FSP-WDL-001), Grease Trap Cleaning Certificate (FSP-GTC-001), Hazardous Waste Manifest (FSP-HWM-001).

6. Equipment Maintenance¶

Objective: To ensure all processing equipment (grinders, conveyors, metal detectors, optical sorters, expellers, packaging machines) is maintained in a condition that prevents product contamination and ensures consistent CCP/OPRP performance.

Scope: All production, packaging, and ancillary equipment (including HVAC, lighting, compressed air system, and steam boiler) used on Routes A–E.

Procedure Summary: - Preventive maintenance (PM): PM schedule maintained in CMMS (Computerized Maintenance Management System) with tasks, intervals, and responsible technicians. Critical equipment (metal detectors, sorters, expellers, grinders) have PM intervals ≤ 3 months. Non-critical (conveyors, fans) ≤ 6 months. PM tasks include: lubrication (food-grade NSF H1), belt tensioning, bearing replacement, screen inspection, seal replacement, calibration verification. - Corrective maintenance: Any equipment breakdown reported via work order (FSP-MWO-001). Prioritized: critical (production-stopping) within 2 hours, non-critical within 48 hours. Post-repair, equipment is cleaned and inspected by QA before production resumes. Metal detector functionality verified with test wand before re-start. - Spare parts management: Critical spares (metal detector test pieces, sorter nozzles, hammer mill screens, gaskets, bearings) maintained in locked spare parts inventory. Minimum stock levels defined; reorder point monitored monthly. - Contractor management: External maintenance contractors must sign in at reception, receive food safety induction, and be escorted in production areas. Contractor tools inspected for cleanliness and foreign material risk before entering production. Work area segregated during repairs; area cleaned and released by QA after contractor departure.

Frequency: Per PM schedule (ongoing), corrective as needed.

Responsibility: Maintenance Engineer (D. Osei), QA Supervisor (C. Singh).

Records: Preventive Maintenance Schedule (FSP-PMS-001), Work Orders (FSP-MWO-001), Equipment Calibration Log (FSP-CAL-001), Contractor Entry Log (FSP-CEL-001).

7. Personnel Hygiene¶

Objective: To ensure all personnel, visitors, and contractors entering food handling areas maintain a level of personal hygiene that minimizes the risk of microbiological and physical contamination of flaxseed products.

Scope: All employees, temporary workers, visitors, and contractors entering any production, packaging, storage, or QA laboratory area.

Procedure Summary: - Hand washing: Hands must be washed using the following method: wet hands with warm water (35–45°C), apply antimicrobial soap, scrub for ≥ 20 seconds covering all surfaces (palms, backs, between fingers, under nails), rinse, dry with disposable paper towel, use paper towel to close tap. Hand washing stations equipped with foot-operated or sensor-activated taps and liquid soap dispensers. Stations located at all production entrances (minimum one per door), in break rooms, and in washrooms. Signage posted at each station illustrating proper hand washing technique. - Uniforms: All production personnel must wear facility-laundered uniforms (light-coloured, no external pockets above waist). Uniforms provided and laundered by facility. Changing into uniform before entering production is mandatory. No personal clothing exposed. - Hairnets and beard covers: Hairnets (disposable, non-woven polypropylene) must cover all scalp hair completely. Beard covers required for any facial hair longer than 3 mm. No hairnets with metal snaps/clips allowed. Hairnets replaced after each break. - Jewelry policy: No jewelry (rings, watches, bracelets, necklaces, earrings, piercings) permitted in production areas. Only plain wedding band allowed if covered with a disposable nitrile glove taped at wrist. Body piercings must be taped over. No false eyelashes or fingernails permitted. - Fingernails: Fingernails must be clean, short (not extending beyond fingertip), and free of nail polish, artificial nails, or nail enhancements. - Illness reporting: Any employee with symptoms of vomiting, diarrhoea, fever, or jaundice must report immediately to supervisor and be excluded from production duties. Return-to-work requires symptom-free period of ≥ 48 hours without medication and clearance from occupational health advisor. - Injuries: All cuts, burns, abrasions must be bandaged with a visible blue-detection bandage. Gloves worn over bandages. Minor injury first-aid kit available in each production area (blue bandages, blue detectable plasters only). - Toilet facilities: Clean, ventilated, with hand washing station, soap, paper towels, and closed bins for paper towel disposal. Cleaning log posted inside. Toilets cleaned daily by sanitation staff. Hand washing sign on door exit — "Did you wash your hands?" - Footwear: Dedicated slip-resistant, closed-toe, non-marking safety shoes provided. Footbaths (quaternary ammonium-based sanitizer) located at all production entrances — step through and hold for 3 seconds minimum.

Frequency: Continuous (all personnel, every entry). Compliance audited weekly by QA Supervisor.

Responsibility: Training Coordinator (G. Kim), QA Supervisor (C. Singh), Production Manager (B. Martinez).

Records: Personnel Hygiene Training Log (FSP-HYG-001), Illness Report Form (FSP-ILL-001), Hand washing Observation Checklist (FSP-HWO-001), Return-to-Work Clearance (FSP-RTW-001).

8. Supplier Control¶

Objective: To ensure that all incoming raw materials (flaxseeds, packaging materials, processing aids, chemicals) meet defined food safety, quality, and regulatory requirements before acceptance.

Scope: All raw material suppliers of whole brown and golden flaxseeds, packaging materials (bags, foil, labels, jerry cans, caps), processing aids (nitrogen gas, tocopherols), cleaning chemicals, and maintenance items that contact food.

Procedure Summary: - Supplier approval: All new suppliers must complete a Supplier Questionnaire (FSP-SUP-001) covering: food safety certifications (GFSI recognized — BRCGS, FSSC 22000, SQF, IFS), third-party audit reports (within last 12 months), product specifications, COA template, HACCP documentation, allergen controls, and GMO status. A desk audit is conducted by Supply Chain Manager. High-risk suppliers (raw seeds) require an on-site audit before approval. - Approved Supplier List (ASL): All approved suppliers listed in FSP-ASL-001 with approval date, product category, certification status, and rating. Updated monthly. - Performance monitoring: Suppliers rated quarterly on: non-conformance rate (COA discrepancies, foreign material complaints), on-time delivery, audit score, and responsiveness to corrective actions. Scorecard system: 0–2 = poor (review/suspend), 3–6 = acceptable, 7–10 = preferred. Suppliers scoring ≤ 2 for two consecutive quarters placed on probation or delisted. - Incoming verification: Each lot of raw flaxseeds must be accompanied by COA showing results for: moisture (≤ 10%), foreign material (≤ 1%), aflatoxin (≤ 4 ppb total, ≤ 2 ppb B1), ochratoxin A (≤ 5 ppb), Salmonella (negative/25 g), E. coli O157 (negative/25 g). Third-party lab analysis performed on first three lots from new suppliers and quarterly on existing suppliers.

Frequency: Continuous (new approvals), quarterly (performance review), per-lot (COA review).

Responsibility: Supply Chain Manager (E. Rossi), QA Supervisor (C. Singh).

Records: Supplier Questionnaire (FSP-SUP-001), Approved Supplier List (FSP-ASL-001), Supplier Scorecard (FSP-SSC-001), Certificate of Analysis Log (FSP-COA-001), Supplier Audit Report (FSP-AUD-001).

9. Receiving & Storage¶

Objective: To ensure that all incoming materials are received, inspected, and stored under conditions that maintain product safety, quality, and integrity, with proper stock rotation and allergen segregation.

Scope: All receiving activities for raw flaxseeds, packaging materials, chemicals, and other supplies. Storage covers raw material warehouse (ambient), finished product warehouse (ambient), and chemical storage room.

Procedure Summary: - Receiving inspection: Each incoming vehicle inspected for cleanliness, odours, pest evidence, and temperature before offloading. Cargo seals checked against seal number on shipping documents. Material transferred to quarantine area and labelled "HOLD — Awaiting Inspection." QA pulls representative sample (Codex sampling plan for bulk grains). Visual inspection for mould, insects, discoloration, foreign material. COA verified against specification. Lot released only after QA sign-off (FSP-RCV-001). - FIFO (First-In, First-Out): All raw materials and finished products stored using FIFO method. Each pallet labelled with: product name, lot number, production date, quantity, and status (Quarantine/Released/Rejected). Warehouse management system (WMS) enforces FIFO at picking. Physical FIFO audit performed monthly by QA. - Temperature monitoring: Ambient storage area monitored continuously by calibrated data loggers. Temperature range: 18–25°C. Relative humidity: ≤ 65%. Alarms set for deviation beyond 25°C or 70% RH. Loggers downloaded and reviewed weekly. Finished oil product (Route E) stored in separate temperature-controlled room at 15–20°C (dark). Temperature checked manually twice daily and logged. - Allergen segregation: Brown flaxseeds and golden flaxseeds stored on separate, clearly labelled pallet racks (different warehouses or separated by minimum 3 m clear gap). Dedicated colour-coded pallets (blue = golden, red = brown). Milled products (Routes C, D) stored in separate room. No shared handling equipment between brown and golden without full cleaning protocol. Allergen handling procedures posted in storage area. - Rejected material: Rejected raw materials or finished products moved to red-tagged "REJECT" area in locked cage. Held pending disposition (return to supplier, rework, or destruction).

Frequency: Per receipt, daily (temperature/HVAC), monthly (FIFO audit).

Responsibility: Supply Chain Manager (E. Rossi), QA Supervisor (C. Singh), Warehouse Lead.

Records: Receiving Inspection Log (FSP-RCV-001), Temperature Log (FSP-TMP-001), FIFO Audit Checklist (FSP-FIFO-001), Lot Release Form (FSP-LOT-001), Rejected Material Log (FSP-REJ-001).

10. Chemical Control¶

Objective: To prevent chemical contamination of flaxseed products through the proper approval, receipt, storage, handling, labelling, use, and disposal of all chemicals used within the facility.

Scope: All chemicals entering the facility including cleaning and sanitation chemicals (detergents, sanitizers, lubricants), pest control chemicals (rodenticides, insecticides), laboratory chemicals (reagents, standards, culture media), and maintenance chemicals (paints, adhesives, sealants, oils).

Procedure Summary: - Approved chemical list: Only chemicals listed on the Approved Chemical Register (FSP-CHEM-001) may be used. All chemicals must be food-grade, NSF-registered (or equivalent), and have a valid Safety Data Sheet (SDS). New chemicals require QA approval via Chemical Approval Request (FSP-CAR-002) before purchase. - Safety Data Sheets (SDS): Current SDS for every approved chemical maintained in two locations: (1) QA office (master binder), (2) Chemical storage room (quick-reference binder). SDS updated within 30 days of supplier revision. Annual audit of SDS binder. - Secondary containers: Any chemical transferred from its original container to a secondary container (e.g., spray bottle, dispensing jug) must be immediately labelled with: chemical name, hazard pictograms, concentration, and date of transfer. Secondary containers must be food-grade HDPE or approved material. No unlabelled containers permitted — zero tolerance. - Storage: Chemicals stored in a dedicated, locked, ventilated chemical storage room (separate from food, packaging, and finished products). Room has: secondary containment (bunded shelving or spill pallets), spill kit (acid/alkali/organic), eyewash station, emergency shower (tested weekly), and exhaust ventilation. Flammable chemicals stored in flammable-liquid safety cabinet. Incompatible chemicals stored separately (acids away from bases, oxidizers away from flammables). - Lubricants: Only NSF H1 food-grade lubricants used in production equipment where incidental food contact is possible. H1 lubricant inventory maintained; non-food-grade lubricants (NSF H2) used only in areas where no food contact possible and are labelled in red.

Frequency: Continuous (upon receipt/use), SDS review quarterly, physical inventory quarterly.

Responsibility: QA Supervisor (C. Singh), Maintenance Engineer (D. Osei), Chemical Room Steward.

Records: Approved Chemical Register (FSP-CHEM-001), Chemical Approval Request (FSP-CAR-002), Chemical Receiving Log (FSP-CRL-001), Spill Incident Report (FSP-SIR-001), SDS Inventory (FSP-SDS-001).

11. Foreign Material Control¶

Objective: To minimize the risk of physical contamination (metal, glass, hard plastic, wood, stones, and other foreign bodies) in flaxseed products through proactive identification, control, and monitoring of potential foreign material sources.

Scope: All production areas, packaging areas, maintenance areas, and incoming materials (raw seeds, packaging components).

Procedure Summary: - Glass and brittle plastic register: A comprehensive register (FSP-FMC-001) is maintained listing every item of glass, rigid plastic, and other brittle materials in production and storage areas. This includes: light fixtures, windows (sealed, non-opening), gauges (dial faces), computer screens (production terminals), clocks, mirrors, and plastic bins/scoops. Each item assigned a unique number, photographed, and inspected quarterly for cracks, chips, or damage. Items found damaged trigger immediate replacement and a product hold/impact assessment. - Glass and plastic policy: No glass or brittle plastic is permitted in production or storage areas unless on the Glass/Brittle Plastic Register. Any intentional glass or brittle plastic brought in for maintenance must be pre-approved by QA and logged in/out. During construction/renovation, all glass/plastic materials are recorded and work area is sealed. - Wood policy: No wooden pallets, tools, or utensils permitted in production or packaging areas. All pallets are plastic or heat-treated (ISPM-15 marked) for storage use only. Wooden pallets are not allowed inside the building — product transfer occurs at the dock with plastic pallets only. Any wood found in production is immediately removed and logged. - Metal control: Metal detectors (CCP 1 and CCP 2) are the primary control. Additionally, all incoming raw seeds pass through pre-cleaning magnets (rare-earth plate magnets, ≥ 10,000 gauss) at receiving and pre-grind. Magnets cleaned daily and gauss reading verified monthly with a gaussmeter (target ≥ 10,000 gauss). All hand tools used in production are stainless steel and controlled via tool register (tool shadow boards, daily tool count). - Personal belongings control: No personal items allowed in production (pen, keys, mobile phones, coins, loose change). All personal belongings stored in lockers in changing room. Pens used in production must be metal-detectable (all-stainless steel, no plastic caps). Production operators carry only approved items on a retractable lanyard.

Frequency: Daily (magnet cleaning, tool count), monthly (gaussmeter verification), quarterly (glass/brittle plastic register inspection), continuous (wood prohibition).

Responsibility: QA Supervisor (C. Singh), Production Manager (B. Martinez), Maintenance Engineer (D. Osei).

Records: Glass & Brittle Plastic Register (FSP-FMC-001), Magnet Gauss Verification Log (FSP-MAG-001), Foreign Material Incident Report (FSP-FIR-001), Tool Inventory Log (FSP-TOOL-001).

12. Training Program¶

Objective: To ensure that all personnel (permanent, temporary, contractor) are trained and deemed competent in the food safety procedures, HACCP principles, personal hygiene, allergen management, and SOPs relevant to their job functions.

Scope: All employees, temporary workers, and contractors working in or entering production, packaging, storage, and QA laboratory areas.

Procedure Summary: - Training matrix (FSP-TRN-002): A master training matrix specifies for each job role the required training modules, initial training frequency, refresher interval, and required competency assessment method. - General Induction (all new hires): Includes food safety policy, personal hygiene, pest awareness, glass/plastic policy, chemical safety, emergency procedures, and facility rules. Duration: 4 hours. Signed acknowledgement. - HACCP Training for CCP Operators (production & packaging operators): Principles of HACCP, CCP identification, critical limits, monitoring procedures, corrective actions, and record keeping. Duration: 8 hours (initial), 4 hours refresher annually. Competency: written test (≥ 80% pass) + practical observation (3 consecutive correct monitoring records). - Hygiene Training (all food handlers): Hand washing technique (with glow-box demonstration), illness reporting, uniform/hairnet policy, jewelry policy, footwear and footbath protocol. Duration: 2 hours initial, 1 hour annual refresher. Competency: practical demonstration + written quiz. - Allergen Training (production, packaging, QA): Allergen cross-contact risks, brown vs. golden segregation, cleaning changeover procedures, supplier control, label verification. Duration: 2 hours initial, 1 hour annual refresher. - SOP Training (job-specific): Standard Operating Procedures for each work station (receiving, pre-cleaning, optical sorting, metal detection, grinding, expeller, filtration, packaging). Includes hands-on demonstration and supervised practice. Signed-off by trainer once trainee demonstrates consistent correct performance over 10 supervised repetitions. - Contractor/Vendor Training (shortened): 15-minute food safety induction covering: hand washing, no jewelry, no eating/drinking, restricted areas, waste handling, and emergency procedures. Logged and signed. - Records: Individual training file maintained for each employee in HR system. File includes: training certificates, competency assessments (written tests, practical observations), training attendance sheets, training schedule. Training records retained for duration of employment + 5 years.

Frequency: New hire (initial), annually (refreshers), competency assessments at each training event.

Responsibility: Training Coordinator (G. Kim), HR Department.

Records: Training Matrix (FSP-TRN-002), Individual Training Record (FSP-TRN-003), Training Attendance Sheet (FSP-TRN-004), Competency Assessment Form (FSP-TRN-005).

Document Control & Revision History¶

Revision	Date	Description of Change	Author	Approved By
00	2026-06-15	Draft PRP document for review	C. Singh	A. Chen
01	2026-07-20	Added Section 11 (Foreign Material Control), expanded Section 7 (Personnel Hygiene), revised Container Waste Management in Section 5	A. Chen	A. Chen

This Prerequisite Programs document is developed in accordance with Codex Alimentarius CAC/RCP 1-1969 Rev. 4 (2003), BRCGS Global Standard for Food Safety Issue 9, and ISO 22000:2018 requirements for PRPs.