Prerequisite Programmes for Food Manufacturing

Programme Summary

Translate food-manufacturing prerequisite requirements into workable controls for facilities, utilities, equipment, materials and personnel. Participants examine how common requirements in ISO 22002-100 interact with the manufacturing provisions of ISO 22002-1. Site-layout exercises and operational evidence help teams identify hygiene gaps, assign control responsibilities and design monitoring and verification arrangements that support their food-safety system.

Training Objectives

1 Clarify common and manufacturing prerequisite programme requirements; 2 Strengthen practical control of contamination pathways; 3 Improve ownership of routine hygiene control activities; 4 Develop evidence based monitoring and verification arrangements; 5 Support prioritised correction of prerequisite programme weaknesses.

Learning Outcomes

1 Map applicable prerequisites to a manufacturing process; 2 Identify hygiene weaknesses from a site layout; 3 Specify controls for materials personnel and equipment; 4 Develop a prerequisite monitoring and verification matrix; 5 Prioritise corrective actions with responsibilities and evidence.

Target Audience

Food safety coordinators; Hygiene managers; Production supervisors; Maintenance engineers; Quality assurance officers; Warehouse supervisors.

Target Industries

Food manufacturing; Beverage manufacturing; Dairy processing; Meat and poultry processing; Bakery manufacturing; Ingredient manufacturing.

Course Contents

• Module 1 PRP Framework and Application: Common requirements and manufacturing additions; Applicable scope and justified exclusions; Relationship with HACCP hazard controls.
• Module 2 Premises Layout and Utilities: Site environment and segregation arrangements; Water air and utility suitability; Drainage waste and contamination pathways.
• Module 3 Equipment and Maintenance: Hygienic equipment construction and accessibility; Planned maintenance and repair controls; Cleaning access and post maintenance release.
• Module 4 Materials Storage and Transport: Purchasing acceptance and material specifications; Storage segregation and stock identification; Handling transport and rework arrangements.
• Module 5 Contamination Prevention: Physical chemical and microbial controls; Allergen segregation and changeover precautions; Foreign body prevention and detection checks.
• Module 6 Cleaning Pest and Waste Controls: Cleaning methods and verification evidence; Pest prevention monitoring and corrective action; Waste handling and disposal arrangements.
• Module 7 Personnel and Product Information: Hygiene facilities and behaviour requirements; Competence visitors and illness reporting; Product information identification and communication.
• Module 8 PRP Verification and Improvement: Monitoring frequency and accountable owners; Inspection evidence and trend evaluation; Corrective priorities and effectiveness checks.

Assessment

• 40 single best answer questions, including applied scenarios; one mark per question.
• 60 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Clean licensed standard extracts and case data allowed; internet, AI and annotated notes prohibited.
• Individual applied assessment (30 minutes): Assess a supplied manufacturing layout and evidence pack. Produce a prerequisite control matrix identifying applicable requirements, observed gaps, monitoring responsibilities, verification evidence and prioritised corrective actions for the selected production area.
• Assessment criteria: Correct application of prerequisite control requirements; Specific monitoring and verification arrangements; Proportionate prioritisation of identified hygiene gaps.
• Pass each component separately: 30/40 written marks (75%) and at least 70% on the applied task.
• All mandatory criteria must pass: Identify and contain an evident contamination route affecting exposed product.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed manufacturing PRP implementation learning; it does not certify a facility or demonstrate complete conformity with ISO 22002 requirements.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

222

Total teaching hoursTotal teaching hoursTotal teaching hours

12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Basic food-hygiene and HACCP awareness is required. Experience with production, maintenance, hygiene or quality activities is recommended.Basic food-hygiene and HACCP awareness is required. Experience with production, maintenance, hygiene or quality activities is recommended.Basic food-hygiene and HACCP awareness is required. Experience with production, maintenance, hygiene or quality activities is recommended.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Review a supplied factory layout for 30 minutes and mark material flows, personnel routes and potential contamination interfaces.Review a supplied factory layout for 30 minutes and mark material flows, personnel routes and potential contamination interfaces.Review a supplied factory layout for 30 minutes and mark material flows, personnel routes and potential contamination interfaces.

End of course assessmentEnd of course assessmentEnd of course assessment

40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.