Chemical & Physical Product Contamination Controls

Aligned with FSSC 22000 Requirements

Requirement Overview

FSSC 22000 requires food businesses to establish and maintain controls that prevent the contamination of food products by chemical and physical hazards. These controls must be risk-based, validated, and part of the site’s overall food safety management system. The goal is to protect product integrity, ensure consumer safety, and comply with regulatory and customer expectations.

Controls must be appropriate to the facility’s processes and product risks and must be reviewed and verified as part of operational PRPs (Prerequisite Programs) and hazard analysis procedures.

Key Compliance Objectives

  • ✓ Identify all potential sources of physical and chemical contamination

    ✓ Apply robust contamination prevention strategies across all areas of the site

    ✓ Validate, monitor, and verify the effectiveness of control measures

    ✓ Maintain detailed documentation for traceability, internal review, and audit readiness

Step-by-Step Compliance Implementation

1.Identify Contamination Risks

  • Hazards to Consider:

    • • Cleaning agents, lubricants, pest control substances

      • Glass, metal, plastic, wood, or debris from equipment or packaging

      • Contaminants introduced via raw materials or damaged infrastructure

    Evidence to Maintain:

    • • Site-specific hazard and risk assessments

      • Integration of physical and chemical hazard analysis in the HACCP plan

      • Equipment and infrastructure inspection logs

2. Implement Control Measures

  • Control Measures May Include:

    • • Segregated storage of chemicals and cleaning tools

      • Use of food-safe materials and lubricants

      • Preventive maintenance programs for equipment and building fabric

      • Installation of physical controls (e.g., mesh screens, filters, covers)

      • Foreign material detection systems (e.g., magnets, sieves, metal detectors, X-ray)

    Evidence to Maintain:

    • • Documented SOPs for cleaning and chemical handling

      • Maintenance and calibration logs

      • Validation records for detection or barrier systems

3. Manage Chemical Controls

  • Specific Requirements Include:

    • • Approved chemical list with Safety Data Sheets (SDS)

      • Designated and labeled chemical storage areas

      • Controlled access and handling by trained personnel

      • Verification of correct chemical concentrations when used in operations

    Evidence to Maintain:

    • • Chemical inventory and SDS documentation

      • Usage logs and dilution verification forms

      • Training records for chemical handlers

4. Monitor and Verify Control Effectiveness

  • Verification Techniques:

    • • Routine inspections of production and storage areas

      • Validation and periodic testing of detection devices

      • Internal audits of chemical storage and handling practices

      • Investigation of any foreign material incidents

    Evidence to Maintain:

    • • CCP/PRP monitoring logs

      • Internal audit and inspection reports

      • Corrective action records following contamination events

Common Audit Findings & Recommended Fixes

Audit Finding Recommended Action
Unlabeled or improperly stored chemicals Implement clear chemical storage protocols and label all containers
Broken or unclean infrastructure Include facility maintenance in regular inspections and audits
Missing checks for detection systems Establish and document routine verification of detection effectiveness
No foreign body risk assessment Incorporate physical hazard analysis in the site’s HACCP plan

Auditor Verification Checklist

During an FSSC 22000 audit, auditors may request:

  • • Physical and chemical hazard assessments within the food safety plan

    • Validated control procedures (e.g., for detection, maintenance, chemical use)

    • Records of equipment checks and detection system calibration

    • Incident investigation reports and follow-up actions

    • Staff training documentation for contamination prevention

Implementation Roadmap

Build a Contamination Control Plan

  • ✓ Conduct risk-based assessments for each processing zone

    ✓ Define critical control points or operational PRPs for high-risk areas

Train and Equip Teams

  • ✓ Train staff on hazard identification and contamination prevention procedures

    ✓ Implement SOPs for chemical handling, maintenance, and tool management

Monitor and Verify

  • ✓ Test detection systems and verify their continued performance

    ✓ Conduct internal inspections of equipment, storage, and operational zones

Improve Continuously

  • ✓ Investigate all contamination incidents thoroughly

    ✓ Update procedures and controls based on audit findings and root cause analysis

Why This Matters?

  • ✓ Reduces risk of contamination-related product withdrawals or recalls

    ✓ Ensures compliance with regulatory and food safety scheme expectations

    ✓ Demonstrates commitment to product safety and due diligence

    ✓ Reinforces customer and stakeholder trust in your processes

Support Tools Available

Food Safety Systems provides:

  • ✓ Templates for chemical and physical contamination risk assessments

    ✓ Validation checklists for foreign material detection equipment

    ✓ SOPs for chemical storage, cleaning, and infrastructure inspection

    ✓ Contamination prevention training materials for food handlers and maintenance staff

GET STARTED NOW

Food Safety Systems is an independent consulting provider. We offer services to help businesses align with FSSC 22000 requirements but are not affiliated with, endorsed by, or certified by the Foundation FSSC. All trademarks and brand names are the property of their respective owners and are used for identification only.

For official FSSC 22000 requirements and scheme documentation, visit: www.fssc.com/fssc-22000