FSSC 22000 Packaging PRP Verification Checklist

Inspection checklist for verifying food packaging prerequisite programs under FSSC 22000 and ISO/TS 22002-4. Confirms PRP controls, records, and supporting evidence are complete, effective, and audit-ready.

Program Scope and Document Control

• PRP scope matches the packaging site, processes, and product types
  Confirm the documented prerequisite program scope covers all packaging lines, warehouses, rework areas, and support functions included in the FSSC 22000 system.
• Current PRP procedures are approved and version-controlled
  Verify procedures, work instructions, and forms are current, approved, and removed from uncontrolled use when obsolete.
• Required PRP records are complete and retained per retention schedule
  Check that records are legible, signed or electronically approved where required, and retained for the defined period.
• Change control records exist for process, material, or layout changes
  Verify changes affecting hygiene, contamination risk, utilities, equipment, or storage were reviewed and approved before implementation.
• Internal audit or verification schedule includes all PRP elements
  Confirm the verification plan covers all relevant PRPs at a defined frequency and overdue actions are tracked to closure.

Facility Layout, Zoning, and Contamination Control

• Raw, WIP, finished goods, and nonconforming material areas are segregated
  Verify physical or procedural segregation prevents mix-up, cross-contamination, and unauthorized movement between zones.
• Traffic flow prevents cross-contamination from forklifts, pallets, and personnel
  Check that people, materials, waste, and equipment move in a controlled manner without backtracking through protected areas.
• Open product or exposed packaging is protected from dust, debris, and splash
  Verify barriers, covers, or process controls protect exposed materials during handling, staging, and transfer.
• Housekeeping prevents accumulation of waste, dust, and damaged packaging
  Inspect floors, ledges, equipment bases, and storage areas for buildup that could attract pests or contaminate product-contact materials.
• Nonconforming or suspect packaging is clearly identified and secured
  Confirm rejected, hold, or quarantined materials are labeled and physically separated to prevent unintended use.

Personnel Hygiene and GMP Controls

• Handwashing and hygiene requirements are posted and followed
  Check that hygiene expectations are visible and employees follow required handwashing, glove, and sanitizing practices.
• Protective clothing and PPE are clean, appropriate, and in use
  Verify hair restraints, smocks, gloves, beard covers, and other PPE are suitable for the area and maintained in sanitary condition.
• Jewelry, personal items, and prohibited behaviors are controlled
  Confirm GMP rules address jewelry, eating, drinking, gum, tobacco, and personal items in production and storage areas.
• Training records show current GMP and hygiene training for relevant staff
  Verify employees assigned to packaging, sanitation, maintenance, and warehouse tasks have current documented training.
• Illness reporting and exclusion rules are documented and communicated
  Check that employee health reporting expectations are available and supervisors know when to restrict or exclude personnel.

Cleaning, Sanitation, and Chemical Control

• Master sanitation schedule is current and completed as planned
  Verify cleaning frequencies, responsible persons, and completion records are available for all relevant areas and equipment.
• Pre-operational or post-clean verification is documented
  Check that sanitation verification results are recorded and any failures are investigated before release of the area or line.
• Cleaning chemicals are labeled, stored, and mixed safely
  Confirm chemicals are identified, segregated from packaging materials, and used according to approved instructions and SDS requirements.
• Chemical containers and spray bottles are not reused without identification
  Verify secondary containers are labeled with contents and hazard information where required.
• Sanitation records show corrective actions for missed or failed cleaning tasks
  Review records for documented follow-up, re-cleaning, and supervisor review when sanitation tasks are incomplete or ineffective.

Pest Control, Utilities, and Maintenance

• Pest control devices are mapped, intact, and serviced on schedule
  Check that traps, bait stations, and monitoring devices are identified on a current site map and records are current.
• No evidence of pest activity is present in production or storage areas
  Inspect for droppings, gnaw marks, nesting material, insects, or other indicators of infestation.
• Compressed air, water, and other utilities are controlled for food packaging use
  Verify utility points used near exposed packaging are maintained to prevent contamination and are monitored where applicable.
• Preventive maintenance is current and does not create contamination risk
  Check maintenance records for overdue work, lubricant control, loose parts, and post-maintenance cleaning or release checks.
• Temporary repairs are controlled and approved
  Confirm temporary fixes are documented, time-limited, and do not expose product or packaging to contamination or foreign material.

Traceability, Storage, and Audit Readiness

• Packaging materials are stored off the floor and protected from damage
  Confirm pallets, racks, and coverings protect materials from moisture, contamination, crushing, and mix-up.
• Lot identification and traceability are maintained from receipt to use
  Verify incoming lots, internal transfers, and finished packaging records support one-step-forward and one-step-back traceability expectations.
• FIFO or FEFO controls are followed where applicable
  Check that inventory rotation prevents use of expired, obsolete, or aged packaging materials.
• Calibration or verification records are current for relevant monitoring devices
  Review records for scales, thermometers, metal detectors, or other devices used to verify PRPs or packaging controls.
• Open corrective actions from prior audits are closed or on an approved plan
  Confirm prior findings have documented root cause, correction, corrective action, and effectiveness verification where required.