Introduction

Many food manufacturers in Malaysia believe their ISO 22000 system is “complete” because the procedures are documented.

But during audits, auditors still issue NCRs.

This is one of the biggest reasons food businesses fail ISO 22000 audits.

At CAYS Scientific, we frequently see companies with:

One frozen food manufacturer came to us after receiving 9 NCRs during their ISO 22000 surveillance audit.

The root cause was not HACCP documentation.

It was weak implementation of operational prerequisite programmes (OPRPs) and poor daily operational discipline.

Why PRPs and Operational Controls Matter in ISO 22000

Many companies focus too much on HACCP charts and CCP monitoring.

But auditors today are paying closer attention to operational control effectiveness.

Without strong PRPs and operational controls, your HACCP plan becomes unreliable.

What Are PRPs in ISO 22000?

PRPs (Prerequisite Programmes) are the basic environmental and operational conditions needed to produce safe food.

In ISO 22000, PRPs help reduce the likelihood of hazards occurring before they become critical issues.

The Hidden Problem: Systems That Look Good but Fail in Reality

This is extremely common in food manufacturing.

The documents appear complete.

But when auditors walk the production floor:

• Staff cannot explain procedures
• Monitoring records are incomplete
• Cleaning activities differ from SOPs
• Operational controls are inconsistently applied
• Shift workers bypass controls during busy production periods

Real Audit Scenario

A sauce manufacturer had documented allergen segregation procedures.

But during the audit:

• Scoops were shared between allergen and non-allergen ingredients
• Color coding was inconsistent
• Staff were unclear about cleaning validation steps

Why Food Businesses Struggle with ISO 22000 Operational Controls

1. Too Many Complicated Procedures

Many systems are overly theoretical.

Staff do not understand them.

• Procedures are skipped
• Records become “tick-and-sign”
• Monitoring loses effectiveness

2. Poor Staff Training

ISO 22000 operational controls involve everyone:

• Production operators
• Cleaners
• Storekeepers
• Maintenance teams
• Supervisors

3. PRPs Are Not Reviewed Regularly

• New products
• New equipment
• Layout modifications
• Increased production volume

4. Management Focuses Only Before Audit

Last-minute preparation almost always fails.

Real Consequences of Weak PRPs and Operational Controls

Typical Consultant vs CAYS Scientific

Step-by-Step: How We Strengthen PRPs and Operational Controls

Step 1: Factory Reality Assessment

We observe actual operations, not just documents.

Step 2: PRP & OPRP Mapping

Controls aligned with production flow and hazards.

Step 3: Simplified Operational Documentation

Simple systems staff can actually follow.

Step 4: Staff Engagement Training

Practical demonstrations using real production scenarios.

Step 5: Internal Audit & Continuous Improvement

Practical audits that simulate real certification audits.

Real Results from CAYS Scientific

Example Case

FAQ – ISO 22000 PRPs and Operational Controls

What are PRPs in ISO 22000?
PRPs are operational and environmental conditions required to maintain food safety.

What is the difference between PRP and OPRP?
PRPs are general preventive controls, while OPRPs are specific monitored controls identified through hazard analysis.

Why do companies receive NCRs related to operational controls?
Because of weak implementation, poor staff understanding, and inconsistent monitoring.

How often should PRPs be reviewed?
At minimum annually, or whenever processes/products change.

Can SMEs implement ISO 22000 effectively?
Yes — if systems are practical, simplified, and operationally aligned.