Iso Ts 220024 Checklist Top -

ISO/TS 22002-4 standard, which was recently updated in , specifies the requirements for establishing, implementing, and maintaining Prerequisite Programmes (PRPs) for food safety in the manufacturing of food packaging

A comprehensive checklist for this standard focuses on controlling hazards that could be introduced during the production, handling, and storage of packaging materials to ensure they do not compromise food safety. Core Checklist Categories

Below are the primary areas covered in an ISO/TS 22002-4 compliance checklist: Establishment & Layout

: Evaluation of the building’s construction, environment, and internal layout to ensure proper traffic patterns and separation of raw and finished goods. Utilities & Infrastructure

: Monitoring of air quality, water supply, and compressed gases to prevent contamination during the manufacturing process. Waste Management

: Procedures for the scheduled removal and hygienic disposal of waste and hazardous substances. Equipment Maintenance

: Ensuring all machinery is designed for easy cleaning and undergoes regular preventive maintenance. Cleaning & Sanitization

: Verification of cleaning programs, including the use of approved agents and monitoring of their effectiveness. Pest Control

: Implementation of detection and prevention programs to avoid harbourage and infestation. Personnel Hygiene

: Standards for workwear, handwashing, and staff facilities (canteens/changing rooms) to minimize human-borne contamination. Strategic Importance

provides the overarching management framework, the ISO/TS 22002 series provides the detailed operational requirements

necessary for specific sectors. Organizations often use these checklists during internal audits to identify gaps before seeking official FSSC 22000 certification

ISO TS 22002-1 Compliance Checklist | PDF | Hygiene - Scribd

The ISO/TS 22002-4 checklist is the essential roadmap for food packaging manufacturers looking to secure FSSC 22000 certification and ensure the highest standards of food safety. By focusing on Prerequisite Programs (PRPs), this technical specification helps you control biological, chemical, and physical hazards before they ever reach the consumer.

Below is an in-depth guide and checklist of the top requirements to help your facility stay compliant and audit-ready. 1. Facility Construction and Layout

Your physical site is the first line of defense against external contamination. An auditor will look for:

Clear Boundaries: Are the edges of your facility well-defined to prevent unauthorized access or environmental pollution?

Hygienic Design: Do internal structures (walls, floors, and ceilings) feature smooth, washable surfaces that don't trap dust or moisture? iso ts 220024 checklist top

Traffic Patterns: Is there a logical flow for people and materials that prevents the unintentional mixing of raw materials and finished goods? 2. Utilities and Environment

Utilities like air, water, and energy must be managed to ensure they don't introduce hazards.

Air Quality: Is ventilation sufficient to control dust and condensation, especially in areas where packaging is exposed?

Water Safety: Is water used for cleaning or direct contact monitored for potability? Non-potable systems must be separate and clearly labeled.

Lighting: Are light fixtures protected (shatterproof) to prevent physical contamination in the event of a bulb breaking? 3. Equipment Suitability and Maintenance Equipment used in production must be "food-safe" by design.

Cleanability: Are product-contact surfaces smooth, non-absorbent, and easily accessible for sanitation?

Preventative Maintenance: Is there a documented schedule for all equipment? Maintenance requests that impact food safety must be prioritized.

Food-Grade Lubricants: Are any lubricants that might contact the packaging certified for incidental food contact? 4. Contamination Prevention & Pest Control

The "top" priority in any ISO/TS 22002-4 audit is the active prevention of pollution.

Physical Hazards: Is there a strict policy for glass, brittle plastics, and sharp objects? Retractable "snap-off" knives are typically banned.

Chemical Migration: For printed packaging, are there controls to prevent ink from "offsetting" from the outer surface to the food-contact surface?

Pest Management: Do you have a comprehensive program including regular inspections, bait maps, and documented sighting logs? 5. Personnel Hygiene and Facilities Safety starts with the people on the floor.

Handwashing Stations: Are they located at the entrance to production areas and equipped with hands-free taps and single-use towels?

Protective Clothing: Do workers wear appropriate, clean uniforms without pockets above the waist to prevent items from falling into products?

Health Status: Is there a policy for reporting illnesses and covering open wounds before entering the production zone? 6. Supplier Management & Traceability You are only as safe as the materials you buy.

ISO/TS 22002-4:2013 (recently updated to ISO 22002-4:2025) establishes the prerequisite programs (PRPs) for food safety specifically for food packaging manufacturing . It is typically used in conjunction with ISO 22000 for organizations seeking FSSC 22000 certification . Top Requirements Checklist

A comprehensive audit checklist for ISO/TS 22002-4 typically includes the following critical areas : ISO/TS 22002-4 standard, which was recently updated in

Establishment & Layout: Evaluation of the environment, location, and internal design to ensure traffic patterns and equipment layout minimize contamination risks .

Utilities: Management of water supply, air quality (ventilation/compressed air), and lighting .

Waste Management: Procedures for waste handling and the adequacy of drains and drainage .

Equipment Suitability: Hygienic design of machinery, maintenance schedules, and the safety of food packaging contact surfaces .

Purchased Materials: Selection and management of suppliers and rigorous inspection of incoming raw materials .

Contamination Prevention: Specific measures to prevent microbiological, physical, chemical, and allergen contamination, as well as chemical migration .

Cleaning & Sanitation: Verification of cleaning schedules and effective pest control programs .

Personnel Hygiene: Requirements for staff facilities, personal cleanliness, and health monitoring .

Rework & Storage: Proper handling of reworked materials, storage conditions, and transport security .

Food Defense: Implementation of biovigilance and bioterrorism prevention measures . Critical Implementation Steps

To successfully review and implement these standards, organizations often follow a structured workbook approach :

Familiarization: Understanding the relationship between ISO 22000 and the sector-specific ISO 22002-4 .

Gap Analysis: Using a checklist to identify current operational gaps compared to the standard .

HACCP Implementation: Integrating hazard analysis specifically for packaging materials .

Internal Audit Training: Ensuring the quality team can effectively use the ISO/TS 22002-4 checklist for ongoing compliance .

For organizations using professional toolsets, resources like the SafetyCulture FSSC 22000 Checklist or the IFSQN Implementation Package provide structured templates for these reviews .

Are you preparing for an internal audit or an official FSSC 22000 certification? Part 4: Common Non-Conformances & Fixes | Clause

This guide is structured to help you audit, develop, or maintain your Prerequisite Programmes (PRPs) against the specific requirements of ISO/TS 22002-1:2009 (often used in conjunction with ISO 22000).

Part 4: Common Non-Conformances & Fixes

Part 2: The Walk

At 9:00 AM, the auditor arrived. Elena Okafor was a legend in the industry—a tall, silver-haired woman who had shut down three plants in the past year. She carried a leather binder, not a tablet. And she smiled.

“Good morning. I’d like to start with the ‘top management checklist’—clause 7. Leadership and commitment.”

Maya’s heart hammered. The checklist item read:

7.1 Has top management demonstrated active involvement in the FSMS (Food Safety Management System), including resource allocation and site walkthroughs?

Leo stepped forward. “Of course. I’m hands-on.”

Elena tilted her head. “Wonderful. Show me the last three months of your documented floor tours, with follow-up actions and closure dates.”

Silence.

Maya knew the truth. Leo’s “walkthroughs” were yelling at supervisors from the mezzanine. No records. No actions.

“I’ll take that as a gap,” Elena said softly, making a note. “Let’s continue.”

Introduction: Why ISO/TS 22002-4 Matters

In the world of food safety, the focus is often on HACCP (Hazard Analysis and Critical Control Points). However, without a solid foundation, HACCP is like building a house on sand. That foundation is your Prerequisite Programmes (PRPs).

For food packaging manufacturers, the global benchmark for these PRPs is ISO/TS 22002-4. This technical specification works hand-in-hand with ISO 22000 (Food Safety Management Systems) to ensure that the environment where packaging is produced—from a plastic bottle to a cardboard box—does not become a source of contamination.

If you are looking for the top checklist to audit your facility against ISO/TS 22002-4, you have come to the right place. This checklist is structured across the 19 critical clauses of the standard.

19. Documentation and Records

ISO/TS 22002-4 is about evidence. "If it isn't written down, it didn't happen."

Checklist Item: Is the PRP manual current and approved by management?
Checklist Item: Are all monitoring records (pest logs, temp logs, cleaning checklists) filed and legible?
Checklist Item: Is there a system for corrective action when a PRP fails (e.g., a pest trap is full)?

9. Pest Control

Pest management plan (monitoring, thresholds, control methods).
Bait/chemical use documented and placed away from crop contact.

2. Internal Layout and Workspace

Internal design must prevent cross-contamination between raw materials, work-in-progress, and finished goods.

Checklist Item: Is there a logical flow of materials (raw → processing → finished) to avoid backtracking?
Checklist Item: Are change rooms and washrooms physically separated from production areas by airlocks?
Checklist Item: Are there designated "clean" and "dirty" corridors or zones?
Checklist Item: Is the ceiling height adequate for cleaning, with no false ceilings harboring dust?

2. Utilities & Air Quality

[ ] Compressed air: Is oil-free air used where contact occurs? Are filters (0.01 micron) and regular microbial tests performed?
[ ] Ventilation: Are air intake and exhaust systems filtered to prevent dust, insect, or mold entry? Is positive air pressure maintained in clean zones?
[ ] Water quality: Is water used in cooling or cleaning potable? If non-potable water (e.g., for cooling towers) is used, are pipes color-coded and backflow preventers installed?
[ ] Steam: If steam contacts packaging, is it culinary grade (free of amines or treatment chemicals)?

Common Non-Conformities (What the Top Auditors Find)

When reviewing real ISO/TS 22002-4 audits, these are the most frequent failures:

| Area | Non-Conformity | |------|----------------| | Compressed air | No microbial testing or filter changes recorded | | Inks & adhesives | Missing migration data for low-contact surfaces (e.g., bag-in-box outer layers) | | Maintenance | Temporary repairs (tape, wire) left for >48 hours | | Personnel | Operators wearing personal gloves from home (no proof of food-grade) | | Traceability | Mixed scrap recycling bins causing rework contamination |

A top checklist explicitly includes verification activities for these weak points.