For many food manufacturers, ISO 22000 certification seems straightforward—until the first audit arrives.
In reality, a significant number of companies fail or receive major nonconformities during their initial ISO 22000 audit.
So why does this happen?
Most failures are not caused by technical complexity, but by misunderstanding how ISO 22000 actually works.
Failing does not always mean rejection. It often includes:
Major nonconformities raised
Inability to proceed to Stage 2 audit
Extended corrective action periods
Delayed certification timeline
These outcomes increase:
Cost
Stress
Operational disruption
Common issues:
Documents prepared purely for audit
Procedures not followed on the shop floor
Staff unaware of documented controls
Auditors typically find:
“Paper systems” with no implementation
Inconsistent practices between shifts
Frequent audit findings include:
Generic hazard analysis copied from templates
Hazards not linked to actual processes
Incomplete evaluation of biological, chemical, and physical risks
ISO 22000 requires:
Process-specific hazard identification
Justified risk evaluation
Clear linkage to control measures
Many companies struggle with:
Over-designating CCPs
Misclassifying OPRPs
Poor justification for control categorization
Auditors often ask:
Why is this a CCP?
What happens if this control fails?
If answers are unclear, major nonconformities are likely.
Common PRP failures include:
Inadequate cleaning and sanitation records
Weak pest control monitoring
Poor maintenance and calibration control
Inconsistent personal hygiene practices
PRPs form the foundation of ISO 22000—if they fail, the system collapses.
Typical audit observations:
Operators unaware of food safety hazards
Supervisors unclear about control measures
HACCP team members unable to explain decisions
ISO 22000 requires:
Competency-based training
Ongoing awareness—not one-time courses
Auditors often detect:
Management review done only on paper
Food safety objectives not monitored
Top management absent during key discussions
ISO 22000 demands:
Leadership commitment
Decision-making involvement
Resource allocation
Without management support, audits usually fail.
Many companies:
Fix problems temporarily
Fail to identify root causes
Repeat the same issues during audits
Auditors look for:
Root cause analysis
Effective corrective actions
Preventive thinking
Common findings include:
Traceability exercises not tested
Incomplete supplier or batch records
Recall procedures not verified
ISO 22000 expects:
End-to-end traceability
Tested and documented recall systems
First-time ISO 22000 applicants often:
Underestimate audit depth
Rely heavily on templates
Lack internal food safety maturity
Rush implementation timelines
ISO 22000 is:
A management system
Not a one-time certification project
Conduct a realistic gap assessment
Customize hazard analysis to actual processes
Strengthen PRPs before HACCP
Train staff based on job roles
Involve top management early
Perform internal audits seriously—not symbolically
Many failures occur because:
HACCP plans exist
But system controls are missing
ISO 22000 requires:
HACCP plus
Management control
Performance monitoring
Continuous improvement
Most food manufacturers do not fail ISO 22000 because the standard is too hard.
They fail because the system is not truly implemented.
When ISO 22000 is treated as a daily operational tool, first-audit success rates increase significantly.
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