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Food Safety Enhancement Program Manual

Appendix V - Food Safety Enhancement Program - Prerequisite Programs - Generic Model

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The prerequisite program generic model was developed by the Canadian Food Inspection Agency (CFIA) for establishments to use as a template when developing their written prerequisite programs. The model is in an auditable format outlining a company standard(s) and providing control measure(s) (monitoring and verification) associated with the standard(s). Developing and implementing plant specific prerequisite programs remain the property and responsibility of the individual establishment. The generic model must be customised to reflect individual establishment environmental conditions and commodity specific program requirements.

The prerequisite program generic model is written in bullet format to ensure clarity. For each bullet, the basic criteria that must be met for the establishment standard is outlined below the bullet and an example of the control measures (monitoring, deviation and verification) associated with that standard is provided in the subsequent columns. The establishment's standard should reference any applicable sop's or company manuals. The Canadian Food Inspection Agency will be auditing prerequisite programs at the sub-element level which may consist of a combination of bullet items (see Appendix II). During the development of their prerequisite programs, an establishment may combine bullet items within their respective programs.

Company name: xyz

* All of the variables x and y will be replaced with company specific information.
* Where applicable, tasks for certain bullets will be divided by departments when generated by the operator.
* The specific program requirements and specific information, where applicable, will have to be added to the "what/how".
* Details of information required is contained below.


Bullet :

Who: Position or Person Doing the"What"

What/how: Duties, limits, forms completed and any references to additional manuals e.g. sanitation manual. It also documents
How the"What" is carried out

When: (Frequency) How often the"Who" does the"What"

Deviation: Procedures to be followed by the "who" when a deviation occurs, including corrective action

Verification: Includes who does the verification, how it is done and at what frequency. Ensures that the "what" is carried out.

Records: what/how  -  systems check  -  corrective actions (If different from above)


A 1.1.1
Building facility not located in close proximity to any environmental contaminants and the surrounding/roadways are free of debris and refuse, adequately drained and maintained to minimize environmental hazards.

Standard - criteria associated with debris and refuse, possible contamination from neighbours, property drainage and maintenance/cleanliness of property.  Site plan demonstrates building location and property layout.

Who: Position x

What/how:
Walk around the building exterior and perform a visual inspection to ensure that, as per specific program requirements, the building facility not located in close proximity to any environmental contaminants and the surrounding/roadways are free of debris and refuse, adequately drained and maintained to minimize environmental hazards. The site plan from the blueprints is utilized and confirmed to be accurate. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x , the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made , by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx, where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx  -  Blueprint xxx


A 1.1.2
Building exterior designed, constructed and maintained to prevent entry of contaminants and pests, e.g., no unprotected openings, air intakes are appropriately located, and the roof, walls and foundation are maintained to prevent leakage.

Standard - Adescription of "or exterior building plan indicates material Amake-up" and condition of the exterior of the building (includes roof, walls and foundation) and air intakes/vents. Criteria must address the need to prevent pest and contaminant entry into the building.

Who: Position x

What/how:
Walk around the building and perform a visual inspection to ensure that, as per the specific program requirements, the building exterior is designed, constructed and maintained to prevent entry of contaminants and pests. The position x will check that there are no unprotected openings, air intakes are appropriately located, and the roof, walls and foundation are maintained to prevent leakage. In addition a check will be performed against the blueprints for the building exterior to ensure accuracy. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position x records the description of the deviation, the corrective action the date of completion and on form xxx. If required, the cause of the problem and the action plan to prevent reoccurrence of the problem is also recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. If required, the cause of the problem and the action plan to prevent reoccurrence of the problem is also recorded on form xxx.

Records: Form xxx& - Blueprint xxx


A 2.1.1
Where required/ appropriate, areas of the establishment are provided with an adequate number of conveniently located hands free hand washing stations with trapped waste pipes to drains, sanitizer hand dips and boot dips/sprays which effectively controls the potential for cross contamination.

Standard - "description of" or interior building plan indicates the type and location of wash stations, sanitizer hand dips and boot dips/sprays within the establishment. Description must also include the term "hands free" and the fact that they are adequately trapped to drains. Criteria must also include strength of sanitary fluids and a requirement that they are adequately filled or operating appropriately.

Who: Position x

What/how:
Tour the establishment and perform a visual inspection to ensure that, as per specific program requirements, areas of the establishment are provided with an adequate number of conveniently located hands free hand washing stations with trapped waste pipes to drains and sanitizer hand dips. A check is made against the blueprints to ensure accuracy. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx

The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations areOnce every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made , by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx

Records: Form xxx - Blueprint xxx


A 2.1.2
Floors, walls, ceilings constructed of material that is durable, impervious, smooth, cleanable, and suitable for the production conditions in the area and where appropriate joints are sealed and angles are coved to prevent contamination and facilitate cleaning.

Standard - "description of" or interior building plan indicates the material make-up of floors, walls and ceilings. These materials need to meet all regulatory requirements and include coving, if necessary. Description of expected condition of floors, walls and ceilings to be included in the standard.

Who: Position x

What/how:
Tour the establishment and perform a visual inspection to ensure that, as per specific program requirements, existing floors, walls, ceilings constructed of material that is durable, impervious, smooth, cleanable, and suitable for the production conditions in the area and where appropriate joints are sealed and angles are coved to prevent contamination and facilitate cleaning. The blueprint is utilized and checked for accuracy. Records, signs/dates on form xxx. 

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx - Blueprint xxx


A 2.1.3
Floors, walls and ceilings composed of materials that are listed in the "reference listing of accepted construction materials, packaging materials and non-food chemical products", published by CFIA or the manufacturer has a "letter of no objection" from Health Canada. and will not result in the contamination of the environment or food.

Standard - indicates that the materials used in the floors, walls and ceilings in the production areas are identified in the Reference Listing or have a letter of "no objection" by Health Canada. For new materials ordered (e.g. new construction) a description of how materials are ordered, how they are received and how the establishment ensures construction meets company specifications is needed.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection to ensure that, as per specific program requirements, the blueprints reflect the actual conditions in the establishment and that floors, walls and ceilings composed of materials that are listed in the "reference listing of accepted construction materials, packaging materials and non-food chemical products", published by Agriculture and Agri-food Canada or the manufacturer has a "letter of no objection" from health Canada and will not result in the contamination of the environment or food. A check is made to ensure that the materials listed on the blueprints schedules are approved. For any new materials or construction a check for approval is made when blueprints are drafted. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx

The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx  -  Blueprints xxx


A 2.1.4
Floors sufficiently sloped to permit liquids to drain to trapped outlets.

Standard - describes slope of floor necessary for adequate drainage (e.g. no pooling of water. Includes a description and/or drawing showing location of trapped drains in the establishment.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection to ensure that, as per specific program requirements, floors are sufficiently sloped to permit liquids to drain to trapped outlets. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx


A 2.1.5
Ceilings, overhead structures, stairs, and elevators designed, constructed and maintained to prevent contamination.

Standard - Describes the criteria for overhead structures, stairs and elevators to ensure they do not contaminate product. Description must include the condition required for them to be acceptable (e.g. no rust, flaking etc.).

Who: Position x

What/how:
Tours the establishment and performs a visual inspection to ensure that, as per specific program requirements, ceilings, overhead structures, stairs, and elevators are maintained to prevent contamination. In the instances of new construction, ensures that ceilings, overhead structures, stairs, and elevators designed and constructed to prevent contamination. Records, signs/dates on form xxx.

When: Once per x Or as per new design or Construction

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made , by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx  -  Blueprints xxx


A 2.1.6
Windows are sealed or equipped with close fitting screens and where there is a likelihood of breakage of glass windows that could result in the contamination of food, the windows are constructed of alternative materials or are adequately protected.

Standard - "description of" or interior building plan indicates location and material "make-up" of all windows located in the processing areas of the establishment.  Description should identify criteria for windows and include a requirement that they be tightfitting and/or adequately screened.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection utilizing the blueprints to ensure that, as per specific program requirements, windows are sealed or equipped with close fitting screens and where there is a likelihood of breakage of glass windows that could result in the contamination of food, the windows are constructed of alternative materials or are adequately protected. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx

The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx - Blueprints xxx


A 2.1.7
Doors have smooth, non-absorbent surfaces and are close fitting and self closing where appropriate.

Standard - "description of" or interior building plan indicates location and material "make-up" of all doors (including curtains, employee doors, bay doors etc.). Description must identify criteria for condition of doors including tight fitting and self closing where required.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection utilizing the blueprints to ensure that, as per specific program requirements, all doors have smooth, non-absorbent surfaces and are close fitting and self closing where appropriate. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx

The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx  -  Blueprints xxx


A 2.1.8
Buildings and facilities are designed to facilitate hygienic operations by means of a regulated flow in the process from the arrival of the raw material at the premises to the final product. The traffic pattern of employees, product flow and equipment prevents contamination of food through physical or operational separation. Procedures and policies are used to prevent potential cross-contamination during the production process (e.g., employee work descriptions, allergen program, etc.). Where appropriate, blueprints and/or process flow diagrams are available.

Standard - schematic diagram (form 4) outlines employee and product flows in the facility. Potential cross contamination points are to be identified for raw and finished product movements. Description should include specific points in the facility where job practices may result in cross contamination if specific operational job practices are not followed outside of normal GMPs. Description of allergen program needed, if applicable.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection to ensure that, as per specific program requirements, the buildings and facilities are designed to facilitate hygienic operations by means of a regulated flow in the process from the arrival of the raw material at the premises to the final product. The traffic pattern of employees, product flow and equipment prevents contamination of food through physical or operational separation. Blueprints and/or process flow diagrams are utilized and accuracy is checked. Records, signs/dates on form xxx

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx  -  Blueprints xxx  -  Flow Diagram xxx


A 2.1.9
Living quarters/areas where animals are kept are separated and do not open directly into food handling, processing, packaging areas. Physical and operational separation of incompatible operations are provided where cross-contamination may result.

Standard - "description of" or interior building plan indicates location of living quarters, animal housing or other non-compatible areas (e.g. retail outlets). Criteria must describe the measures in place to prevent direct entry or contact between these areas and the processing handling and packaging areas.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection to ensure that, as per specific program requirements, living quarters/areas where animals are kept are separated and do not open directly into food handling, processing, packaging areas. Also a tour and visual inspection is performed to ensure that, as per specific program requirements, physical and operational separation of incompatible operations are provided where cross-contamination may result. Blue prints and flow diagrams are utilized and checked for accuracy. Records, signs/dates on form xxx

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx - Blueprint xxx - Flow Diagram xxx


A 2.2.1
Lighting is appropriate such that the intended production or inspection activity can be effectively conducted, does not alter food colour and meets the respective commodity standards.

Standard - describes lux requirements for the establishment including location of inspection points. Criteria includes that the lights are operational.

Who: Position x

What/how:
Tours the establishment and performs an inspection utilizing a light meter to ensure that, as per specific program requirements, lighting is appropriate such that the intended production or inspection activity can be effectively conducted, does not alter food colour and meets the respective commodity standards (standards are listed here). Records, signs/dates on form xxx

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx


A 2.2.2
Light bulbs and fixtures located in areas where there is exposed food or packaging materials are of a safety type or are protected to prevent contamination of food in case of breakage.

Standard - describes the protective coverings of lights. Criteria must include where they are needed and located in the facility.

Who: Position x

What/how:
Tours the establishment and performs a visual inspection to ensure that, as per specific program requirements, light bulbs and fixtures located in areas where there is exposed food or packaging materials are of a safety type or are protected to prevent contamination of food in case of breakage. Records, signs/dates on form xxx.

When: Once per x

Deviation:
The position x makes an assessment as to whether food safety has been compromised and records findings on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx.   The position x records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Verification:
Once every x, the position y observes the position x in the performance of his monitoring function and reviews all records that have been completed since the last verification. All records are signed and dated by the position y at the time of verification. If deviations are encountered, an assessment is made, by the position y, as to whether food safety has been compromised and recorded on form xxx. If food safety has been compromised the product is held, tested and subsequently released, reworked or destroyed and recorded on form xxx. The position y records the description of the deviation, the corrective action and the date of completion on form xxx. Where required, preventative corrective actions are developed by performing a root cause analysis, describing the preventative measures, date for completion and person responsible and is recorded on form xxx.

Records: Form xxx

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