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Perform HACCP Prerequisite Program Assessment using eAuditor

HACCP Prerequisite Program (PRP) refers to the foundational environmental and operational conditions required to support an effective Hazard Analysis and Critical Control Points (HACCP) system. These programs establish the basic hygienic and safety practices necessary to prevent food safety hazards before the HACCP plan is implemented.

Performing a HACCP Prerequisite Program Assessment using eAuditor ensures a comprehensive and systematic evaluation of all foundational food safety practices, facility hygiene, equipment maintenance, and operational controls. This critical assessment supports the effective implementation of a HACCP system by confirming that all baseline conditions preventing contamination and food safety risks are rigorously maintained and documented in real time.

1. Purpose of the Assessment

The primary goal of conducting the HACCP Prerequisite Program assessment with eAuditor is to:

• Validate that prerequisite programs such as GMPs, SSOPs, pest control, and supplier management are fully operational and effective.
• Identify gaps or deviations in basic hygiene, equipment sanitation, and environmental controls before they impact food safety.
• Support HACCP’s focus on critical control points by ensuring all upstream controls are stable and compliant.
• Provide documented evidence for internal and external audits with timestamped reports and photographic proof.
• Streamline corrective action assignment and tracking to foster continuous improvement.

2. Key Assessment Areas in eAuditor

Facility and Environmental Controls

Ensuring the physical environment where food is processed or handled is safe and hygienic is fundamental. The inspection should verify:

• Cleanliness:  Regular cleaning of floors, walls, ceilings, and work surfaces , free from dust, residues, and buildup.
• Pest Control: Evidence of pest monitoring devices (traps, bait stations), absence of pest activity signs, and documentation of pest control service schedules.
• Lighting: Proper illumination that allows safe operation and inspection, with protective covers to prevent broken glass contamination.
• Ventilation: Adequate airflow to control humidity, temperature, and airborne contaminants; regularly cleaning or replacement of  filters.
• Waste Management: Waste bins should be covered, emptied frequently, and located away from food handling areas. Drains must be clean and functional to prevent water pooling or contamination.

eAuditor Features:
Use detailed checklists with condition statuses (e.g., compliant, needs attention), photograph areas showing good practice or concerns, and add comments to describe observations clearly.

Equipment and Maintenance

Maintaining of equipment to avoid contamination or process failures:

• Cleaning and Sanitation: Verify that cleaning schedules exist, are followed, and recorded. Equipment parts in contact with food should be corrosion-resistant and free of damage.
• Calibration: Regular calibration and verification of temperature probes, scales, and other critical instruments to ensure accuracy.
• Repairs: Check for any pending repairs that could cause contamination or downtime, and confirm maintenance logs are up to date.
• Safe Storage: Hygienical storing of tools and utensils to avoid contamination between uses.

eAuditor Features:
Record inspection results using pass/fail toggles, attach maintenance records, and capture close-up photos of any equipment damage or dirt.

Personnel Hygiene and Training

Worker hygiene and knowledge are vital for food safety:

• Training Verification: Confirm all food handlers have up-to-date training in hygiene, sanitation, and hazard awareness.
• Hygiene Practices: Assess the availability and use of handwashing stations, soap, and hand sanitizers. Observe workers for proper handwashing and use of gloves where applicable.
• Protective Clothing: Check that employees wear clean uniforms, hairnets, gloves, and other PPE, and also ensure regular cleaning and replacement of these items.
• Health Policies: Ensure protocols are in place for reporting illness or symptoms that could risk contamination.

eAuditor Features:
Upload training certificates, use checklists to confirm compliance, and document observations with photos or notes.

Sanitation Standard Operating Procedures (SSOPs)

Sanitation ensures the elimination of contaminants and prevention of cross-contamination:

• Cleaning Procedures: Evaluate if detailed cleaning procedures exist for all areas and equipment, including frequency and methods.
• Chemical Use: Inspect storage of cleaning chemicals for proper labeling, segregation, and safe handling.
• Verification: Check whether the team tests sanitation effectiveness regularly.
  (e.g., ATP testing, visual inspections).
• Cross-Contamination Controls: Ensure cleaning tools and procedures prevent transferring contaminants between raw and finished product areas.

eAuditor Features:
Use form fields to document compliance, attach SOP documents, and track sanitation schedules.

Supplier and Raw Material Control

Food safety begins with controlling inputs:

• Approved Suppliers: Verify that all raw materials come from approved sources with documented safety certifications.
• Incoming Inspection: Confirm that staff inspect raw materials for signs of contamination or damage upon arrival.
• Allergen Controls: Check procedures to prevent cross-contact, correct labeling, and proper storage of allergenic ingredients.
• Traceability: Ensure systems exist to trace raw materials from receipt through production to finished goods.

eAuditor Features:
Attach supplier approval records, document inspection findings, and include allergen control checklists.

Water Quality and Management

Water is a potential contamination source if not controlled:

• Source Verification: Confirm that staff use potable water sources and test them regularly for microbiological and chemical contaminants.
• System Integrity: Inspect for backflow prevention devices and ensure plumbing maintenance prevents contamination.
• Wastewater Management: Verify that staff dispose of wastewater properly and prevent it from contacting food areas.

eAuditor Features:
Upload water testing reports, checklist inspection of plumbing, and note corrective actions.

3. Automation and Workflow Features in eAuditor

• Mobile and Offline Access: Perform inspections on-site using tablets or smartphones, even without internet access, syncing later.
• Photographic Evidence: Attach images to inspection points for clear visual documentation of compliance or issues.
• Conditional Logic: Customize forms to show follow-up questions only if non-compliance is detected, improving focus and efficiency.
• Automated Alerts: Notify quality managers immediately when critical issues arise, enabling rapid response.
• Task Assignment and Tracking: Assign corrective actions with deadlines, priority levels, and responsible persons directly in the app.
• Comprehensive Reporting: Generate detailed, audit-ready reports with timestamps, photos, and sign-offs automatically.

Summary

Using eAuditor to perform a HACCP Prerequisite Program assessment empowers food safety teams to maintain rigorous control over the basic but vital environmental and operational conditions needed for food safety. By verifying facility hygiene, equipment maintenance, personnel practices, sanitation, supplier controls, and water quality in a structured, real-time digital format, organizations can prevent contamination risks early, support HACCP plan effectiveness, and demonstrate compliance to auditors with comprehensive documentation. This approach promotes continuous improvement, traceability, and accountability across the entire food production process.

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