A Guide to Operational Prerequisite Programs (OPRPs) in Food Safety Systems

What is an Operational Prerequisite Program (OPRP)?

An OPRP is a targeted food safety control measure used to mitigate specific hazards identified through risk assessment. OPRPs focus on operational hazards that require measurable limits, continuous monitoring, and verification. These essential controls bridge the gap between baseline Prerequisite Programs (PRPs) and Critical Control Points (CCPs), keeping the entire food safety system reliable.

Importance

Experts recognized that many control points were being mismanaged because they were too significant for foundational hygiene but fell short of CCPs. ISO introduced the OPRP to cover this middle ground, ensuring common everyday lapses won’t undermine the entire Food Safety Management System (FSMS). Here are some specifics:

• Targeted hazard control: Addressing the middle ground improves overall hazard management. These risks can compound if continuously ignored.

• Complement to CCPs: OPRPs support CCPs by handling the operational aspects.

• Operational consistency: Standardizing control measures at operational levels improves process reliability and minimizes variability that could lead to unsafe products.

• Food safety risk reduction: Effective OPRPs control contamination routes, successfully lowering the incidence of foodborne illnesses. The simple act of sanitizing surfaces, for instance, has significantly reduced pathogen presence on food.

• Regulatory compliance: Implementing this program is a guaranteed way to achieve ISO 22000 certification. This also supports other compliance with regulations in different jurisdictions.

How is an Operational Prerequisite Program (OPRP) Different from a CCP and a PRP?

Many food manufacturers, retailers, and safety practitioners struggle to distinguish between the three core food safety concepts. Review this guide to define the nuances and effectively integrate all three for comprehensive product safety:

What are Examples of Operational Prerequisite Programs (OPRPs)?

Examining real-world applications of the Operational Prerequisite Program can help food businesses distinguish between PRPs and CCPs. Here are some concrete examples:

• Cleaning and sanitation of equipment: The CDC reports that millions of Americans get sick from foodborne illnesses. OPRP-level sanitation prevents cross-contamination and reduces the microbial load of pathogens like Listeria, Salmonella, and E. coli.

• Temperature control during processing: The USDA notes that bacteria can double in number every 20 minutes at 40°F–140°F. Proper temperature control can prevent this problem, especially in meat, dairy, and ready-to-eat foods.

• Allergen management procedures: Millions have food allergies. OPRP controls ensure separation, correct labeling, and validated cleaning processes, reducing the instances of anaphylaxis.

• Pest control measures: The EPA highlights that pests (e.g., rodents, cockroaches) are known carriers of over 35 diseases. Clean, dry, and well-kept facilities repel these pests.

• Supplier control and verification: Foodborne illnesses, often originating from adulterated raw materials, cause over 400,000 fatalities annually. Beyond ensuring robust traceability, verifying supplier adherence to standards significantly reduces the risk of contamination.

How are Operational Prerequisite Programs (OPRPs) Identified and Validated?

An operational prerequisite program in food industry helps identify food safety hazards, analyze them, and validate them through testing, monitoring, and documentation. Following this guide is one of the most effective ways to reduce risks in food handling:

Step 1: Conduct a thorough hazard analysis

Identify specific biological, chemical, physical, or allergen hazards at each process stage. Utilize a multidisciplinary team and process flow mapping to prevent overlooking risks, such as metal contamination during cutting operations, which requires careful mapping and review.

Step 2: Determine control measures

These specify how each identified hazard will be managed. Select controls aligned with regulations and scientific data to ensure effective risk reduction. An example is installing and maintaining a metal detector for the product before final packaging to mitigate physical risk.

Step 3: Define clear, measurable limits

Limits on time, temperature, concentration, and pH show whether the controls set are functioning properly. Base these limits on validated standards and regulatory requirements to increase accuracy. Namely, the sanitation chemical concentration should be maintained between 150 to 200 ppm to guarantee microbial efficacy.

Step 4: Perform validation and verification

Validation confirms that the control measure can effectively reduce the hazard, while verification ensures it’s consistently applied. Using scientific evidence is a must to strengthen system performance. To illustrate, microbiological testing shows how effective food safety guidelines and controls are in removing pathogens like Listeria or Salmonella.

Step 5: Establish robust monitoring procedures

Continuous monitoring ensures limits are met in real time. On top of assigning specific personnel, create detailed forms to prevent deviations from going unnoticed. For example, operators should meticulously record the core product temperature for every batch during the critical cooking phase.

Step 6: Train staff effectively

Training ensures employees understand procedures, limits, and monitoring requirements. Getting hands-on with regular refresher sessions significantly improves compliance. To give you an idea, specialized training is essential to help sanitation staff accurately measure and verify required chemical concentrations.

Step 7: Document all processes

Documentation includes monitoring logs, deviations, corrective actions, and validation records. Centralize and organize files for easy retrieval, which supports both traceability and audits. Specifically, maintaining digital copies of daily cleaning verification records is vital for demonstrating compliance over time.

Step 8: Review and update periodically

Regular reviews ensure the OPRP remains effective despite changes in equipment, ingredients, or regulations. Conducting annual reviews or initiating updates after significant nonconformities maintains system relevance. For instance, it’s essential to update limits and procedures after switching to new equipment, like a high-speed filler.

Sodexo has greatly benefited from a comprehensive platform that digitized its entire control and monitoring process, directly improving its health and safety outcomes. It has also increased real-time visibility into the operations, allowing workers at different levels to immediately and correctly act on issues.