PAS 220:2008 Pre-requisite Programmes on Food Safety for Food Manufacturing Self-Assessment

Checklist

Conformance
Sect. Requirements Remarks
Yes No

4.0 Construction and layout of buildings

4.1 General requirements

Are buildings designed, constructed and

maintained for food processing operations?

Are buildings and facilities of sound

construction and in good repair?

4.2 Environment

Is the establishment located in an area that is

free from environmental contaminants?

Are roadways, and the immediate vicinity

leading to the establishment, free from
potential contaminants?

Is the effectiveness of measures taken to

protect against potential contaminants from
local environment reviewed periodically?

4.3 Locations of establishments

Are the boundaries clearly identified?

Is access to the establishment controlled?

Is the outside area maintained in good repair

and vegetation tended to, or removed?

Is any standing water observed in the area?

5.0 Layout of premises and workspace

5.1 General requirements

Are buildings and facilities design to prevent

the entrance and harbouring of pests?

Are buildings and facilities laid out in such a

way as to permit easy and adequate cleaning?

5.2 Internal design, layout and traffic patterns

Are buildings and facilities laid out in such a

way as to allow for a proper process flow from
receiving to storage of goods?

Are openings intended for transfer of materials

designed to minimise entry of foreign matter
and pests?

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 Conformance
Sect. Requirements Remarks
Yes No

5.3 Internal structures and fittings

Are process area walls and floors washable or

cleanable?

Are materials resistant to the cleaning system

applied?

Are floors of water-proof, non absorbent

washable, non-slip and non-toxic materials
without crevices?

Are floors sufficiently sloped for liquids to

drain?

Are walls smooth and without crevices and

light coloured?

Are ceilings and overhead fixtures designed to

minimise build up of dirt and condensation?

Are external opening windows, roof vents and

fans where present screened?

5.4 Location of equipment

Is equipment designed and located so as to

facilitate monitoring?

Is equipment located to permit access for

operation, cleaning and maintenance?

5.5 Laboratory facilities

Are microbiology laboratories designed,

located and operated so as to prevent
contamination (people, buildings and
products)?

Do microbiology laboratories open directly onto

a production area?

Are in-line and on-line test facilities controlled

to minimise risk of product contamination?

5.6 Temporary / mobile premises and vending

machines

Are temporary structures designed, located

and constructed to avoid pest harbourage and
potential contamination of products?

Are hazards associated with temporary

facilities assessed and controlled?

Are hazards associated with vending machines

assessed and controlled?

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 Conformance
Sect. Requirements Remarks
Yes No

5.7 Storage of food, packaging materials,

ingredients and non-food chemicals

Do facilities used to store ingredients,

packaging and products provide protection
from dust, condensation, drains, waste and
other sources of contamination?

Are storage areas dry and well ventilated?

Are monitoring and control of temperature and

humidity applied where required?

Are storage areas designed or arranged to

allow segregation of raw materials, work in
progress and finished products?

Are all materials and products stored off the

floor and with sufficient space between the
material and the walls to allow inspection and
pest control activities to be carried out?

Are storage areas designed to allow

maintenance and cleaning?

Are storage areas designed to prevent

contamination and minimise deterioration?

Are separate secure, locked or access

controlled storage areas provided for cleaning
chemicals and other hazardous substances?

6.0 Utilities - air, water, energy

6.1 General requirements

Are the provision and distribution routes for

utilities to and around processing and storage
areas designed to minimise the risk of product
contamination?

Are utilities quality monitored to minimise

product contamination risk?

6.2 Water supply

Is the supply of potable water sufficient to meet

the needs of the production process(es)?

Are specified water quality requirements such

as facility for storage, distribution and control of
temperature, where required, available?

Does water used as a product ingredient,

including as ice or steam or in contact with
products or product surface, meet specified
quality and microbiological requirements?

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 Conformance
Sect. Requirements Remarks
Yes No

Is water used for cleaning or applications

where there is an indirect product contact (e.g.
jacketed vessels, heat exchangers) meet
specified quality and microbiological
requirements?

Are checks conducted on chlorinated water to

ensure residual chlorine level at the point of
use remains within specified limits?

Does non-potable water have a separate

supply system that is labelled and is not
connected to the potable water system and is
prevented from reflux into the potable system?

6.3 Boiler chemicals

Are boiler chemicals approved food additives

which meet relevant additive specifications?
OR

Are additives safe for use in water intended for

human consumptions and approved by the
relevant regulatory authority?

Are boiler chemicals stored in a separate;

secure (locked or otherwise access controlled)
area when not in use?

6.4 Air quality and ventilation

Has the facility established requirements for

filtration, humidity (RH%) and microbiology of
air used as an ingredient or for direct product
contact?

Has a control system been put in place where

the temperature and / or humidity are deemed
critical?

Is the control system monitored?

Is ventilation provided to remove excess or

unwanted steam, dust, odours and
condensation?

Is ventilation provided to facilitate drying after

wet cleaning?

Is air supply quality controlled to minimise risk

from airborne microbiological contamination?

Are protocols for air quality monitoring and

control established in areas where product
which support growth or survival are exposed?

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 Conformance
Sect. Requirements Remarks
Yes No

Are ventilation systems designed and

constructed such that air does not flow from
contaminated or raw areas to clean areas?

Are specified air pressure differentials

maintained?

Are air delivery systems accessible for

cleaning, filter changing, and maintenance?

Are exterior air intake ports examined

periodically for physical integrity?

6.5 Compressed air and other gases

Are compressed air, carbon dioxide, nitrogen

and other gases used in manufacturing and / or
filling maintained so as to prevent
contamination?

Are gases intended for direct or incidental

product contact (including those used for
transporting, blowing or drying materials,
products or equipment) approved for food
contact use?

Are gases intended for direct or incidental

product contact (including those used for
transporting, blowing or drying materials,
products or equipment) filtered to remove dust,
oil, and water?

Where oil is used for compressors, is the oil

food grade?

Are requirements for filtration, humidity and

microbiology specified?

6.5 Lighting

Does the lighting provided allow personnel to

operate in a hygienic manner?

Are light fixtures protected to ensure that

materials, product, or equipment are not
contaminated in the case of breakage?

7.0 Waste disposal

7.1 General requirements

Are systems in place to ensure that waste

materials are removed and disposed of in a
manner which prevents contamination of
products or production areas?

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 Conformance
Sect. Requirements Remarks
Yes No

7.2 Containers for waste and inedible or

hazardous substances

Are containers for waste and inedible or

hazardous substances clearly identified for
their intended purposes?

Are containers for waste and inedible or

hazardous substances located in designated
areas?

Are containers for waste and inedible or

hazardous substances constructed of
impervious material which can be readily
cleaned and sanitised?

Are containers for waste and inedible or

hazardous substances closed when not in
use?

Are containers for waste and inedible or

hazardous substances locked where the waste
may pose a risk to the product?

7.3 Waste management and removal

Is waste accumulating in food handling or

storage areas?

Are removal frequencies managed to avoid

accumulations?

Is waste removed daily?

Are labelled materials, products or printed

packaging designated as waste disfigured or
destroyed to ensure that trademarks cannot be
reused?

Are removal and destruction carried out by

approved contractors?

Are records of destruction retained?

7.4 Drains and drainage

Are drains designed, constructed and located

so that the risk of contamination of materials or
products is avoided?

Do drains have the capacity to remove flow

loads?

Do drains pass over processing lines?

Does drainage flow from a contaminated area

to a clean area?

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Sect. Requirements Remarks
Yes No

8.0 Equipment suitability, cleaning and

maintenance

8.1 General requirements

Is food contact equipment designed and

constructed to facilitate cleaning, disinfection
and maintenance?

Are contact surfaces affected by the intended

product or cleaning system?

Is food contact equipment constructed of

durable materials able to resist repeated
cleaning?

8.2 Hygienic design

Does equipment meet established principles of

hygienic design such as having smooth,
accessible, cleanable surfaces and self
draining in wet process areas?

Does equipment meet established principles of

hygienic design such as the use of materials
compatible with intended product and cleaning
or flushing agents?

Does equipment meet established principles of

hygienic design such as framework not
penetrated by holes or nut and bolts?

Are piping and ductwork cleanable, drainable,

and with no dead ends?

Is equipment designed to minimise contact

between the operator's hands and the
products?

8.3 Product contact surfaces

Are product contact surfaces constructed from

materials designed for food use?

Are product contact surfaces impermeable and

free from rust or corrosion?

8.4 Temperature control and monitoring equipment

Is equipment used for thermal processes able

to meet the temperature gradient and holding
conditions given in relevant product
specifications?

Is equipment provided for monitoring and

control of the temperature?

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 Conformance
Sect. Requirements Remarks
Yes No

8.5 Cleaning plant, utensils and equipment

Are wet and dry cleaning programmes

documented to ensure that all plant, utensils and
equipment are cleaned at defined frequencies?

Do the programmes specify what is to be

cleaned (including drains)?

Do the programmes specify who is

responsible?

Do the programmes specify the method of

cleaning, the use of dedicated cleaning tools,
removal or disassembly requirements and
methods for verifying the effectiveness of the
cleaning?

8.6 Preventive and corrective maintenance

Is there a preventive maintenance program in

place?

Does the preventive maintenance program

include all devices used to monitor and / or
control food safety hazards?

Is corrective maintenance carried out in such a

way that production on adjoining lines or
equipment is not at risk of contamination?

Are maintenance requests which impact product

safety given priority?

Do temporary fixes put product safety at risk?

Does a request for a permanent repair included

in the maintenance schedule where a temporary
fix is related to product safety?

Are lubricants and heat transfer fluids food grade

where there is a risk of direct or indirect contact
with the product?

Does the procedure for releasing maintenance

equipment back to production include clean up,
sanitising where specified, and pre-use
inspection?

Do local PRP requirements apply to

maintenance areas and maintenance activities
in process areas?

Are maintenance personnel trained in the

product hazards associated with their
activities?

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 Conformance
Sect. Requirements Remarks
Yes No

9.0 Management of purchased materials

9.1 General requirements

Is purchase of materials which impact food

safety controlled to ensure that the suppliers
can meet specified requirements?

Are incoming materials verified against

specified purchase requirements?

9.2 Selection and management of supplies

Is there a defined process for the selection,

approval and monitoring of suppliers?

Is the process used to manage suppliers

justified by hazard assessment including final
risk to the finished product?

Is the suppliers' ability to meet quality and food

safety expectations, requirements and
specifications taken into consideration?

What are the methods by which the suppliers

are assessed?

Are suppliers monitored to ensure continued

approval status?

9.3 Incoming material requirements (raw /

ingredients / packaging

Are seals on delivery trucks checked?

Are delivery trucks verified to ensure they are

free from infestation, dirt and any
contaminants?

Are delivery trucks transporting ingredients that

require temperature control, properly equipped
with functioning temperature control devices?

Are incoming materials inspected, tested or

covered by COA or COC?

Are incoming materials verified against

specified requirements prior to being
accepted?

Are records of verification kept?

How does the establishment prevent the

unintended use of nonconforming materials?

Are incoming materials that do not conform to

specified requirements segregated?

Are records kept on incoming materials that do

not meet specified requirements?

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 Conformance
Sect. Requirements Remarks
Yes No

Are access points to bulk receiving capped and

kept under lock?

Are unloading of bulk materials only done after

verifying that the materials meet specified
requirements?

10.0 Measures for prevention of cross

contamination

10.1 General requirements

Are programmes in place to prevent, control

and detect contamination?

Are measures to prevent physical, chemical

(including allergens) and microbiological
contamination part of the programmes?

10.2 Microbiological requirements

Are hazard assessment carried out to

determine potential microbiological
contamination sources?

Are areas with potential microbiological

contamination sources identified?

Does the hazard assessment take into

consideration the followings where appropriate
and necessary:
a) Separation of raw materials and finished
products?
b) Structural segregation between raw and
finished?
c) Access control with requirements to change
into required workwear?
d) Traffic patterns including people, materials,
equipment and tools?
e) Air pressure differentials?

10.3 Allergens management

Are allergens present in the product declared

on the labels?

Are allergens that may be present through cross

contact declared on the label or a "may contain"
warning present on the label?

For products intended for further processing and

that contain or may contain allergens, is there a
declaration with the shipment?

Are products protected from unintended

allergen cross contact during:
a) cleaning?
b) line change over practices?
c) product sequencing?

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 Conformance
Sect. Requirements Remarks
Yes No

Is there an allergen management program in

place for handling raw material, finished
product, rework and work in progress?

10.4 Physical contamination

Is there a procedure for handling glass or brittle

material?

Are records of glass breakage maintained?

Are measures in place to prevent, control and

detect any potential physical contaminants?

11.0 Cleaning and sanitising

11.1 General requirements

Are cleaning and sanitising programmes

established?

Are programmes monitored for continuing

suitability and effectiveness?

11.2 Cleaning and sanitising agents and tools

Are facilities maintained in a condition which

facilitates cleaning and or sanitation?

Is equipment easily accessible for cleaning?

Are cleaning and sanitising agents and

chemicals clearly identified and used in
accordance with manufacturer's instructions?

Are cleaning and sanitising chemicals food

grade or approved for use in food processing
establishments?

Can tools be a source of contamination?

11.3 Cleaning and sanitising programmes

Does the organization have a cleaning and

sanitation programme?

Has the cleaning programme been validated to

ensure that all parts of the establishment and
equipment are cleaned / sanitized to a defined
schedule?

Does the cleaning and /or sanitising

programmes specify the followings:
a) Areas, items of equipment and utensils to
be cleaned and / or sanitized
b) Responsibility for the tasks
c) Cleaning / sanitising method and frequency
d) Monitoring and verification arrangements
e) Post clean inspections
f) Pre-start inspections

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 Conformance
Sect. Requirements Remarks
Yes No

11.4 Cleaning in place (CIP) systems

Are CIP systems separated from active product

lines?

Are parameters for CIP systems defined and

monitored including type, concentration,
contact time and temperature?

11.5 Monitoring sanitation effectiveness

Are cleaning and sanitation programmes

monitored for effectiveness?

12.0 Pest control

12.1 General requirements

Are activities to mitigate risks of pest activity

such as cleaning, inspection of trucks and
incoming materials etc. implemented?

12.2 Pest control programmes

Does the organization have a nominated

person or contractor that manages the pest
control programme?

Does the pest control programme identify

target pests, methods of control?

Is there a documented pest control program?

Does the documented programme specify what

chemicals are to be used where?

12.3 Preventing access

Are buildings maintained in good repair?

Are access points such as holes, drains, etc.

sealed?

Are external doors, windows or ventilation

openings screened to prevent entry of insects?

12.4 Harbourage and infestations

Is the area around the facilities free from food

and water?

Are infested materials handled in such a way

as to prevent contamination or propagation?

Are potential pest harbourage when

encountered removed?

Are outside spaces used for storage protected

from pest damage such as bird's droppings?

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Sect. Requirements Remarks
Yes No

12.5 Monitoring and detection

Are there schematic diagram(s) indicating

where traps and bait stations are located?

Are traps and detectors located in key

locations?

Are detectors and traps designed and located

to prevent potential contamination?

Are detectors and traps designed and located

to prevent potential contamination?

Are detectors and traps designed and located

to prevent potential contamination?

Are results of inspections analysed to identify

trends?

12.6 Eradication

Are eradication measures put in place

immediately after an infestation is found?

Are operators applying pesticides trained and

have valid applicator licenses?

Are records of pesticide used maintained on

file?

Do records of application identify the type,

concentrations used and when and where
applied?

13.0 Personnel hygiene

13.1 General requirements

Are hygiene rules and personal behaviour

contingent on the hazard posed to the process
or product?

Are visitors and contractors required to comply

to documented hygiene requirements?

13.2 Personnel hygiene facilities and toilets

Does the establishment provide adequate

numbers, locations and means of hand
washing, drying and sanitising?

Is there an adequate supply of hot and cold or

temperature controlled water, and soap and or
sanitizer?

Are sinks designated for hand washing,

separate from sinks for food use or equipment
cleaning stations?

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Sect. Requirements Remarks
Yes No

Does the establishment provide an adequate

number of toilets with hand washing, drying
and or sanitising facilities?

Does the establishment have hygienic facilities

that do not open directly onto production,
packaging or storage areas?

Does the establishment have adequate

changing facilities for personnel?

Are the changing facilities located in such a

way as to minimize the danger of workwear
being contaminated during the walk to the work
area?

13.3 Staff canteens and designated eating areas

Are staff canteens and designated areas for

food storage and consumption situated in
locations away from production areas?

Are precautions taken to minimize cross

contamination between staff food consumption
areas and production areas?

Are staff canteens managed to ensure hygienic

storage of ingredients?

Are staff canteen(s) managed to ensure

hygienic preparation, storage and serving of
prepared foods?

Is employees own food stored and consumed

in designated areas?

13.4 Workwear and protective clothing

Do personnel who work in areas where

exposed food products and / or materials are
handled wear clothing fit for purpose?

Is workwear free from rips, tears or fraying

materials?

Is clothing mandated for hygienic purposes

used for any other purposes?

Does workwear have buttons?

Does workwear have outside pockets above

the waist?

Does workwear provide adequate coverage

against hair, perspiration, etc ?

Are gloves in use clean and in good

conditions?

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 Conformance
Sect. Requirements Remarks
Yes No

Are hair, beards and moustaches covered?

(Note: unless hazard analysis indicate
otherwise)

Are shoes worn in processing areas fully

enclosed and made of non absorbent material?

Is personal protective equipment maintained in

good hygienic condition?

13.5 Health status

Do employees in food contact operations

undergo medical examination before
employment? (Note: subject to legal
restrictions in the country of operation).

Are additional medicals carried out at defined

intervals?
(Note: subject to legal restrictions in the
country of operation).

13.6 Illness and injuries

Do employees report to management illnesses

that may result in contamination to the food
being processed?
(Note: subject to legal restrictions in the
country of operation)

Are restrictions to handling food or food contact

materials, applied to people known to be
infected with, or carrying a disease or illness
transmissible through food?

Are personnel with wounds or bums required to

cover them?

Is there a policy for reporting of loss of

dressings?

13.7 Personal cleanliness

Are personnel in production areas required to

wash and or sanitise hands:
a) before starting any food activities?
b) immediately after using the toilet or blowing
the nose?
c) immediately after handling potentially
contaminated material?

Are finger nails kept clean and trimmed?

13.8 Personal behaviour

Is smoking, eating and chewing permitted in

designated areas only?

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 Conformance
Sect. Requirements Remarks
Yes No

Is there a policy with regards to wearing of

jewellery in food processing areas?

Are personal items such as smoking materials

and medicines kept in designated areas only?

Are nail polish, false nails and false eye lashes

restricted in food processing and food handling
areas?

Are personal lockers kept free from rubbish

and soiled clothing?

Are employees allowed to keep contact tools

and equipment in their personal lockers?

14.0 Rework

14.1 General requirements

Is rework stored, handled and used in such a

manner that product safety and quality are
maintained?

Is rework easily traceable?

14.2 Storage, identification and traceability

Is stored rework protected from exposure to

microbiological, chemical and physical
contamination?

Is rework containing allergens segregated from

regular non-allergen materials?

Is rework traceable throughout the process?

Are traceability records for rework maintained?

Do records for rework materials contain all the

necessary information for traceability?

14.3 Rework usage

Where rework is added to product in-line, is the

acceptable quantity, type and conditions of the
rework known?

Are the process step, method of addition, and

any required pre-processing stages defined?

Where rework activities involve removing the

product from filled or wrapped packages, are
precautions taken to ensure that the product is
not contaminated with packaging materials?

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 Conformance
Sect. Requirements Remarks
Yes No

15.0 Product recall

15.1 General requirements

Is there a system in place to identify and

segregate products that fail to meet required
food safety standards?

Does the traceability system allow for the

removal of products that fail to meet required
food safety standards?

15.2 Product recall requirements

Does the organization maintain a current list of

key contacts members of the recall team?

Is there a procedure to handle recalls?

In the event of a recall due to immediate

hazards, is there a procedure to review
products produced under similar and same
conditions?

Does the procedure for recall consider public

warnings if the product being withdrawn poses
immediate health hazards?

16.0 Warehousing

16.1 General requirements

Are materials and products stored in clean, dry

and well ventilated locations?

Are materials and products protected from

potential sources of contaminants such as
dust, odour, fumes etc.

16.2 Warehousing requirements

Are conditions in warehouses controlled to

ensure product integrity?

Are products stacked in such a way as to

prevent damage to the bottom layers?

Are chemicals and waste materials stored

separately from raw materials and finished
products?

Are nonconforming materials segregated from

conforming materials?

Is a quarantine area designated for storing

nonconforming materials?

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Sect. Requirements Remarks
Yes No

Does the organization practice First In First Out

(FIFO) or First Expired First Out (FEFO) ?

Are gasoline or diesel powered fork lift used in

food ingredient or product storage areas?

16.3 Vehicles, conveyances and containers

Are vehicles, conveyances and containers in

good state of repair and clean?

Do vehicles, conveyances and containers

provide protection against damage or
contamination to the product?

If trucks, conveyances and containers are used

to carry food and non-food products, is there a
procedure to ensure that there is no possibility
of contamination?

Are bulk containers in use dedicated to food

use only?

Are bulk containers dedicated to specific

materials where required?

17.0 Product information/consumer awareness

17.1 General requirements

Is information on storage, preparation and

serving provided to the consumer?

Can the consumer make an informed decision

on the information provided to them?

17.2 Labelling of pre-packaged foods

Are procedures in place to ensure the

application of correct labels to the products?

18.0 Food defence, biovigilance and

bioterrorism

18.1 General requirements

Has the organization assessed the hazards to

products posed by potential acts of sabotage,
vandalism or terrorism?

Have protective measures been put in place to

guard against potential acts of sabotage,
vandalism or terrorism?

18.2 Access controls

Are sensitive areas within the establishment

access controlled?

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