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FSSC 22000 packaging certification is the food safety management system that the packaging industry uses to show that their products are safe to come into contact with food during production, distribution, and packaging. For companies that sell corrugated packaging, plastic bottles, flexible packaging, glass jars, and metal containers to food and drinks brands, the certification is now being seen as an essential criterion, rather than an added value. The first mandatory step is the gap analysis, which involves evaluating your organization against the ISO/TS 22002-4 standard – a prerequisite program standard which forms the foundation of FSSC 22000, because most first time clients underestimate their needs for change when it comes to hygiene and processes. Legal4sure offers assistance to packaging units for all stages of the FSSC 22000 certification process.
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These steps depict the true nature of the FSSC 22000 packaging certification process as it is carried out in the manufacturing plant, and not an idealized representation of the process. Our consultants take the manufacturer through each step to ensure that the documentation, control processes, and personnel are prepared before the auditors come around. Strict adherence to this order will save a manufacturer the trouble of realizing that there are deficiencies in the FSSC 22000 packaging standards until the auditors highlight them. Our well-structured process helps Indian food businesses identify compliance gaps before an inspection, organise their records, strengthen facility controls and prepare responsible personnel for questions that may be raised during an FDA inspection.
Determine if the package is under Category PM and its specific sub-scope – rigid, flexible, glass, metal, or corrugated, as this will determine what ISO/TS 22002-4 clauses to follow.
Measure how your hygiene, process, and quality systems compare with ISO/TS 22002-4 and FSSC 22000 to get an idea of the work entailed.
Set the documentation system up – the policy, scope, objectives, and roles.
Implement hazard analysis for physical, chemical, and microbiological hazards particular to the packaging material, including risk from migration and contamination.
Develop hygienic design, pest control, cleaning programmes, and maintenance programmes that meet the packaging-specific PRP requirements according to ISO/TS 22002-4.
Prepare procedures, work instructions, and records that provide the auditor with proof that the procedure is implemented, rather than only documented.
Train floor operators and quality personnel on how to describe controls in their own terms because the auditors interview employees during the Stage 2 audit.
Close all gaps identified during internal auditing process in order to avoid having them reappear during the external audit.
Choose a body accredited for Category PM and schedule the Stage 1 and Stage 2 audits together.
Make sure that the management system documentations are complete and ready for audit before proceeding to stage 2.
Go through the complete on-site audit against the standard.
Send corrective action for all the non-conformities raised in the audit as the decision on certification will be taken after addressing the same.
Legal4sure has helped packaging companies in different materials such as rigid plastics, flexible films, corrugated, and glass & metal through FSSC 22000 packaging certification program and every customer receives a consultant assigned to the unit from day one until the certification decision is made.
We prepare and review all documentation, from the FSMS manual to hazard analysis documents, and audit for compliance between documented procedures and actual practice prior to the audit.
We complete the baseline gap analysis in accordance with the requirements of FSSC 22000 for packaging, and develop the implementation plan, acting as your Implementation Consultant to make sure that the project is completed within its timeline.
We perform internal audits according to the criteria used by the certification body, and work on closing out any non-conformances before they become findings.
We assist in selecting the appropriate certified certification body according to your packaging category, coordinate the scheduling of both Stage 1 and Stage 2, and act as your point of contact throughout the process.
Most established brands in food and beverage have made it a requirement for their suppliers to be certified by FSSC 22000 packaging before being accepted for any business deal and not as differentiation. Failure to do this means a unit cannot access vendor panels until it gets a certificate because buyers in EU, US, and Gulf countries consider FSSC 22000 certification as a point of entry to supplier discussion.
Certification requires that hygiene, processing and handling of materials be documented and implemented in the same way throughout all shifts without relying on individual operator skills. It is through this process that consistency of FSSC 22000 packaging compliance is achieved despite staff rotation and increase in volume.
The systematic hazard analysis helps to eliminate hazards before the materials or processes enter the production line of customers. Thus it minimizes the risk of contamination and the expenses involved with the process. Additionally, it leaves a paper trail when an issue arises from the packaging supplier.
This establishes how the entire process of packaging safety will be carried out, from the policy aspect to the scope and responsibilities. The audit is based on this policy.
These include all hazards that are identified for each packaging material, the control measures used, and the limitations imposed on each processing step. This is the technical heart that auditors scrutinize in the second stage.
This includes hygiene in design, facility layout, pest control, and cleaning validation documents that will prevent the manufacturing environment from being a source of contamination. This is an area where many packaging facilities have trouble during the first inspection.
This is an example of how a consignment of packaging material is traceable from the raw material to its final stage of manufacture and can be easily retrieved in case of need. The certification agencies require this to be demonstrated through a mock recall, not merely documented.
There should be an audit trail showing continuous self-auditing activities throughout the year, rather than a one-time internal audit conducted prior to certification.
This record shows how any non-conformities found within the organization or reported by its customers were investigated and prevented from recurring. A poor CAPA log is often an audit red flag.
This is an example of how resin, board, ink, and adhesives suppliers were checked before usage because safety hazards can arise before reaching the plant.
This logs food safety and hygiene training of each individual worker along with their job position and date. During audits, auditors often ask floor staff themselves about what they have been trained in.
Bridging technical complexity and operational excellence across highly regulated global markets.
Supports manufacturers of films, pouches, laminates and flexible packs with food safety controls, hygiene, contamination prevention, traceability and supplier management.
Helps manufacturers of containers, trays, tubs and bottles establish controls for material safety, hygiene, contamination prevention, production processes and traceability.
Covers food-contact material controls, raw material management, hygiene, contamination risks, process control, traceability and supplier evaluation.
Supports manufacturers with controls for raw materials, chemical and material safety, hygiene, contamination prevention, production control and traceability.
Supports manufacturers of bottles, cans, cartons and other beverage packaging with material controls, hygiene, contamination prevention, process controls and traceability
Helps packaging manufacturers establish appropriate controls for material handling, contamination prevention, hygiene, process management and traceability.
Covers raw material controls, printing processes, ink and chemical management, contamination prevention, hygiene and traceability.
Supports manufacturers of closures, caps, lids and other packaging components with supplier controls, material management, hygiene, contamination prevention and traceability.
Helps corrugated box manufacturers implement food safety controls covering raw materials, production hygiene, contamination prevention, storage and traceability.
Supports glass bottle and container manufacturers with controls for raw materials, production processes, foreign-body risks, hygiene, storage and traceability.
Covers material controls, production hygiene, contamination and foreign-body risks, process monitoring, supplier controls and traceability.
Helps manufacturers establish documented controls for materials intended for direct or indirect food contact, including hygiene, contamination prevention and traceability.
Before working with us, most factories ask the same things. These FAQs cover what Legal4sure does and how we support you.
It is a food safety management system standard that applies to manufacturers of food contact packaging material i.e. plastic, glass, metal, corrugated, and flexible packaging. Every unit catering to organized retail, food manufacturers, and exports will most probably have to comply with it, as it is a blend of ISO 22000 & ISO/TS 22002-4.
Both come under category PM and use the same base i.e. ISO/TS 22002-4, although their hazard control varies; rigid packaging concentrates on traceability of resin and hygiene of molding whereas flexible packaging stresses upon lamination and seal integrity. Gap analysis helps in identifying the requirements.
It depends on the size of facility, number of production lines, selected certification body and required assistance during implementation. Usually it includes consultancy, internal preparations and audit fees by the certification body and then periodic surveillance audit fee is added every year.
For units that have a pre-existing quality management system, some internal documentation preparation can be done; however, most units fail to anticipate how thorough the hazard analysis and PRP documentation have to be. An external consultant usually cuts down the time needed for certification and minimizes non-conformities during Stage 2.
There are variations among units, but usually it takes just a couple of months to get through Stages 1 and 2 after the implementation process has started, especially if the documentation and prerequisite programs were ready beforehand.
ISO 22000 lacks packaging-specific PRPs that are covered in ISO/TS 22002-4. That is why purchasers demand FSSC 22000 certification.
Yes – Legal4sure assists packaging manufacturers in the entire FSSC 22000 Certification process, from scope definition and gap analysis through documentation, Certification Body coordination and Stage 1 and Stage 2 audits.
The Certification Bodies conduct annual surveillance audits to verify that the system continues to be used. The failure to do so results in suspension, which means that the unit is removed from the buyer’s vendor list
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